Hurco and Kawasaki Robotics collaborate on CNC machine-tending shelf system
PACs DEFINED
WHERE’S THE MOTION CONTROL?
INTEGRATE OT DATA
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Process malfunction
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How many operators does it take?
Hurco and Kawasaki Robotics collaborate on CNC machine-tending shelf system
Anna Townshend, managing editor
machine input How IO-Link changed data communication
What makes IO-Link fieldbus-independent and integrable with different protocols?
Mike Bacidore, editor-in-chief
and cordsets for equipment builders
Process improvement is like sailing.
With an experienced partner, you can achieve more.
Optimizing processes and maximizing efficiency is important to remain competitive. We are the partner that helps you master yield, quality, and compliance. With real-time inline insights and close monitoring of crucial parameters, we support manufacturers to optimize processes, reduce waste, and increase yield.
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The time value of 80 sextillion configurable components
Q: The supply-chain woes caused by the global pandemic have changed the way that machine builders manage their materials inventories. How has MISUMI addressed ordering, shipping and fulfillment needs of its customers?
A: MISUMI has always been focused on our customers’ time value, committing to reliable, quick delivery and reducing customers’ wasted work and tasks. Our unique business model combines both a manufacturing business that makes and sells components as well as die sets and a distribution business that stocks and sells a wide range of top third-party brands’ parts and consumables for industrial automation, allowing MISUMI to be a one-stop shop for customers (Figure 1).
Through the MISUMI website, customers can quickly find the quality components they need at low costs from top brands. We offer over 20 million parts from more than 3,000 brands with same-day shipping on over 100,000 stocked parts. Seventy percent of our products ship in four days or less.
MISUMI’s online configurator allows customers to easily configure parts with dimensions up to a micron, accounting for 80 sextillion—80 billion x 1 trillion—configurations. Customers can select the part, shape and dimensions needed, and the configurator will instantly generate a part number, pricing and lead time, eliminating the time wasted on waiting on a quote for a custom drawing. Computer-aided design (CAD) models are also available after configuration.
Figure 1: MISUMI focuses on customers’ time value.
HIROSHI ITO
Director of Industrial Electronics, MISUMI USA
Q: On a related note, with machine builders often looking to place smaller orders with the same benefits of volume ordering, how have you accommodated those requests?
A: MISUMI is focused on saving customers’ time. Nearly all of our components do not require any minimum order quantities, and our configurator provides pricing at various quantity breakdowns with quick and reliable shipping.
Every customer order is treated the same, and the first order received will be the first order shipped. All customers have access to our technical support engineers when they need it.
Q: Some machine builders are looking upstream in the supply chain for parts and components that are customized and configured for their needs. What kind of
services can help to minimize engineers’ pain points?
A: Along with MISUMI’s 80 sextillion configurable components, we recognized that we could offer other services to reduce the customers in-house tasks, saving them time. Therefore, our Industrial Electronics team has developed programs for cut-to-length cabling, customized electrical enclosures and custom cable assemblies, all available with no minimum order quantities (Figure 2). We offer multi-conductor power, control, network and robotics cables from 1 to 100 meters in 1-meter increments. Customers can quickly configure the type and length of cable needed on the MISUMI website. This saves customers time, money and space reducing the need to stock bulk cable. Additionally, we offer customized hole drilling and cut outs in electrical en-
closures to accommodate pushbuttons, switches, cables and displays. Customers can send us their drawings and we will have their quote back to them in 2-3 days. We also provide quality and cost-effective custom cable assemblies with a quick turnaround time. We specialize in one piece to a few hundred in quantity and customers will receive their cable assembly within four weeks, including the quotation process.
These services are again part of the time value we offer our customers. By outsourcing these needs, companies can shift their staff’s work to more valuable tasks.
Q: Time is money. What are some strategies machine builders can employ to reduce time to market and ensure a swifter build process?
A: Machine builders are natural problem solvers, and we believe that one strategy for them is to lean on their supplier partner for solutions. Suppliers are experts in their products and can be creative in the ways their products can be used in various applications. Sometimes a new perspective is needed or a supplier can unveil a product that can solve a builder’s problems.
Q: Where is the sweet spot for MISUMI and its ability to help machine builders obtain the products they need?
A: MISUMI’s sweet spot lies in our ability to support small and mid-sized orders for both mechanical and electrical components. Our manufacturing business’ unique method of standardizing custom parts that would require sending drawings out for a quote allows machine builders to configure their part needs in minutes with our online configurator and instantly see pricing and lead times. Furthermore, we have over 20 million off-the-shelf components ready to ship with our distribution model.
For more information, visit www.misumiusa.com.
Figure 2: Cut-to-length cabling, customized electrical enclosures and custom cable assemblies are available with no minimum order quantities.
Mike Bacidore editor in chief mbacidore@endeavorb2b.com
DMC wins ICC Build-a-Thon
DURING THE 2024 Ignition Community Conference (ICC), Inductive Automation announced it would be moving the annual event to a new venue. For more than a decade, each in-person ICC has been held at the Harris Center for the Arts in Folsom, California. The conference has steadily grown in popularity over the years, and the need for a larger site has grown evident with around 1,000 people in attendance this year. The size of ICC has exceeded the Harris Center’s hosting capacity.
Inductive Automation Chief Operating Officer Kat Jeschke announced during the keynote that the Safe Credit Union Convention Center in Sacramento, California, would be home to the 2025 ICC. About 30 miles from Folsom, the convention center is a fully remodeled venue with more than 240,000 sq ft of space.
After watching the live competition, the audience voted and determined that DMC was the 2024 Build-a-Thon champion. Inductive Automation selects projects that use Ignition to receive awards based on a variety of graded criteria each year. Projects deemed noteworthy are featured and named Discover Gallery finalists. Projects that achieve a high level of innovation, impact or are otherwise significant are awarded the Firebrand Award.
2024 Discover Gallery Finalists included:
• end user Saint-Gobain Glass submitted by 2Gi Technologie
• end user Barbados Water Authority submitted by Aquatec
The audience voted and determined that DMC was the 2024 Build-a-Thon champion.
On ICC’s final day, the Build-aThon, an industrial automation building competition, was held. The first round of the event had been livestreamed on YouTube in August. It featured 26 competitors who simultaneously competed for spots in the finals. In the fantasy-themed journey through the Lands of Ignition, system integrators performed tasks and solved puzzles. The first two integrators to finish all challenges—the United Kingdom’s BIJC SCADA Systems and Chicago-headquartered DMC—were invited to the final battle at ICC 2024, live on stage.
• end user Smart Energy Applications submitted by Automation Solutions Ecuador
• Carlton & United Breweries (CUB)
• end user Copower submitted by Dautom
• end user Stonehill Environmental Partners submitted by Edge Controls
• Environmental Operating Solutions
• end user Belden submitted by Flexware Innovation
• end user Murakami Manufacturing USA submitted by Musson Industrial
• end user Northern Wasco County People’s Utility District (NWCPUD) submitted by OS Engineering
• end user Certarus submitted by Streamline Control
• Vertiv.
2024 Firebrand Award Winners included:
DMC’s team included Brandon Tanner, Sheila KennedyMoore and Nicoli Liedtke, who were tasked with programming an Ignition application to control a convenience store with a carwash, gas pump and food mart. The objective was to enable the convenience stores’ branding. To accomplish this, DMC made a high-level map screen displaying each store’s location and status. Users could click on a store location on the screen to see more details. In order to verify each store’s profitability, transaction simulation was employed.
• end user Goodman Fielder submitted by Deloitte
• Fermi National Accelerator Laboratory
• end user Cinfa submitted by IDOM
• Madkour Group
• CertainTeed.
embedded intelligence
Jeremy Pollard jpollard@tsuonline.com
What is a PAC?
DEFINING THINGS IN our orbit can take on the look and feel of an argument. What is a programmable automation controller (PAC)? If you ask 10 people, you might get 10 different answers.
In the late 1960s, the programmable logic controller (PLC) was born. Initial designs used the available chipsets, which were not microprocessor-based. The original PLCs used a bitslice processor. The beginning of the microprocessor-based PLCs couldn’t have begun until 1974 when the Motorola 6800 and Intel 8080 CPUs were released. As we now know, that changed the world in a heartbeat.
The ability to have the computing power in a single chip allowed designers to create magic. The original PLC was pretty basic. It had the computing power to solve ladder logic, read inputs and write to outputs and interface with a programming device. Any additional functions were added using the I/O structure.
So, the historical path of the PLC was market-driven and reactionary to some degree. You could create any control system by inserting modules into the hardware subsystem and distribute them around the process under control.
Enter the PAC. ARC Advisory Group coined this acronym in 2001 to differentiate hardware platforms from the PLC.
The basic premise of the PAC is integration of all of the add-ons into one platform by design. One of the basic differences is the ability to program in all IEC 61131-3 languages. Ladder logic is still king, but function block and structed text are being implemented more often.
Ladder logic is still king, but function block and structed text are being implemented more often.
There was a need to interface with process-based transducers—analog. There was a need to be able to control positioning in machine control; thus, servo and stepper controls were introduced through the I/O system. There was a desire to take the I/O module subsystem to the location of the I/O in the process, and remote I/O was born.
And then and most importantly devices needed to talk with each other—PLC to PLC. Communication protocols were developed to exchange data between devices and thus machines and processes. As the PLC evolved, communication options were integrated into the hardware design.
Technology advancements such as inexpensive memory allowed vendors to create more expansive operating systems to allow for different control strategies, such as sequential function chart and function block. PLC and distributed-control-system (DCS) applications started to encroach on each other’s markets. The lines were becoming blurred.
The real challenge for the controls engineer was to design a functional system and then program the system to perform the required strategy.
To say that all of these add-ons were integrated would have been a stretch. Configuration of most devices was done by setting individual bits in a data file.
These languages are being used in an integrated environment. A single control strategy can employ all five 61131 languages, if desired, and the execution of the programs is accomplished due to the power of the microprocessors in the hardware.
Certain vendors allow the user to execute programs written in computer languages, such as C++ or C#. The PAC is the result of the evolutionary path of the PLC. The keyword here though is integrated.
Motion, communication, analog, discrete and even builtin human-machine interface (HMI) with edge capabilities are integrated into the platform. The software required to program these features is integrated into the integrated development environment (IDE), allowing the developer to seamlessly create control strategies using a tag-based programmatic approach.
The PAC has allowed for complex systems to be developed. One of the major issues of past PLC-based solutions is the ability of the maintenance team to troubleshoot the connected processes. The need for the floor electrician to be fluent in “PLC speak” has been well-documented. The more complex that a PLC system became, the harder it was for efficient and successful troubleshooting.
JEREMY POLLARD, CET, has been writing about technology and software issues for many years. Pollard has been involved in control system programming and training for more than 25 years.
ACOPOS P3
Big impact, small footprint
With the ACOPOS P3, B&R is setting new standards for motion control. This 3-axis servo drive offers a power density of 4 amps per liter, making it one of the most efficient servo drives with integrated safety functions on the market. It also offers unrivaled dynamics and precision, with a sampling time of just 50 µs for the entire controller cascade.
•69% smaller footprint with highest power density
•No additional fans in the control cabinet
•The right solution for every machine
br-automation.com
technology trends
Rick Rice contributing editor rcrice.us@gmail.com
Centralized vs. decentralized motion
ADMITTEDLY, IN OUR WORKFLOWS, we tend to do what we always do unless there is a compelling reason to change. For me, motion control has always been a big main control panel (MCP) with a large section near the bottom dedicated to the bank of servo drives that make up my application. The drives share a common backplane that also acts as a means of heat dissipation, and the physical size of the drives and the heat they produce is a serious consideration. It also determines how big to make the panel and whether I need to include air conditioning to keep the cabinet cool.
Some discussion about the basics of this design approach is in order.
make the most sense. If your design is a lot of spread-out single axes, then decentralized would be better. With the improvement in network technologies, the grouping of axes in a decentralized topology is also a feasible option. Decentralized topology also lends itself to modularity. Machine builders can develop modules independently and then join them together as part of a bigger solution.
Machine builders can develop modules independently and then join them together.
Centralized motion control means the entire group of servo drives are located in the main control panel with power and encoder cables are routed out to each physical motor mounted on your machine. Additional connections might be necessary to provide a home or registration sensor, and all of this requires cable management, not only in the control cabinet, but out to the field, as well. Think of this as a star topology.
With decentralized motion architecture, the drives are located on the machine or process, close to the devices they operate. The obvious advantage here is the reduction in cable length and routing. Now this technique has been further enhanced over the years by the advance of technology. Formerly, servo groups would be moved out of the MCP into smaller control panels mounted directly to the machine. The main power feed would come from the MCP, as well as the appropriate industrial network connecting this satellite group back to the main processor in the MCP.
Now, this can be accomplished, doing away with the remote group altogether. Distributed drive technology combines servo drive and motor into a single package by way of special cabling; each drive/motor is connected to the next one in a daisy-chain configuration with power and network combined in a single media.
From a practical standpoint, if your machine has a lot of coordinated motion, then a centralized motion group would
Consider wiring costs for a moment. If you have a process that is 60 ft long and each station/motor is 5 ft farther from the main control cabinet than the first one, individual encoder and power cable would add up to 5+10+15+20+25+30+35+40+45+ 50+55+60 = 390 ft of cable using a centralized topology. Using the decentralized topology, total cable length would be 60 ft using a central power supply and decentralized drive/motors.
If your design requires localized I/O, then even better because modules can be added at the site of the drive/ motor without having to run separate power and network cables out to it.
Generally, a distributed motion system will comprise a power supply module—aka power interface module—that resides in the main control cabinet. From this module, a single unified cable connects to the first field-mounted/ distributed servo drive and motor or servo drive only. The choice of the combined servo and motor or just the drive depends on the area in which the motor will be located.
Sometimes there is not enough physical space to mount a combination drive/motor so the drive can be mounted near the motor and then a single unified cable completes the connection from drive to motor. Depending on the hardware manufacture, a number of servo/motor or servo-only modules can then be connected to the first field module in a daisy-chain arrangement.
One vendor allows up to 24 nodes per power interface module. To include more than 24 motors, more power interface modules are added to the main control panel. It is important to note that the heat producers, the drive and motor, are no longer present in the control cabinet so the need to dissipate heat in the main panel is greatly reduced.
Another vendor has a power-supply module to which five distributed drives can be connected. They have a separate distributed power module that can be mounted in the field, and five distributed drives can be connected to that field-mounted device in a cascade topology. This particular product offering shares the dc bus, meaning that regenerated power can be shared across the other drives connected to the power module.
Networks vary, but EtherNet/IP with CIP Motion, Profinet, Profibus, CAN and TwinCAT are some popular methods, depending on the hardware vendor.
All of these developments happen because there is a need to make motion easier to design and deploy. Distributed motion allows the designer to consider motion where a pneumatic or small conventional motor might have previously been used. Motor frame sizes as small as 40 mm—a little over 1.5 inches—are possible. For precise movement, the choice of servo over a pneumatic device is obvious.
Most of the vendors mate their decentralized/distributed motion products with the centralized counterpart. This adds familiarity where programming/commissioning are concerned, and this can make a huge difference when deciding whether to expand to this newer technology.
So, armed with this information, do we use centralized or decentralized motion control in our designs? It would seem that the answer lies in the application.
1. Is this a one-off project, meaning that we customize it to suit the job without the expectation of every making a second one?
2. Is the footprint of the machine big or small? If the footprint is, say, 10 ft by 15 ft, do we gain any advantage by mounting the drives on the machine at the location of the motor? For a larger machine, is there clusters of control where two or more servos will be in the same general location?
3. Is there space on the machine frame to mount the distributed servo drives?
4. The routing of cables is always an important part of the design. Is there a cost savings and/or labor savings to machine-locating the drives, or do we eat up the materials savings by needing more time and people to prep the machine body to accept the field-mounted devices?
5. Is it a worthwhile investment to put design time into a more modular approach, using a decentralized system, at the outset? This would come into play where the future design of the machine will expand to include more functions.
technology trends
6. Have you done a cost comparison to the actual physical hardware for a centralized system versus decentralized? Perhaps we save on machine cable but lose the advantage in the overall cost of the components to go to the decentralized method.
7. Does the prospect of adding local I/O connectivity to the distributed drive/motor make this a more attractive direction to take?
8. Is there a requirement for coordinated motion between the various axes? This would tend to point to a centralized solution.
9. Could we incorporate a hybrid solution where part of it is centralized for the coordinated motion parts and the standalone axes could be part of a decentralized architecture? Again, this would be with an eye to keeping the heat signature in the panel to a minimum.
I hope that the questions above can provide some avenues of thought for those who might consider the transition from centralized to decentralized motion control architecture.
Now approaching four decades in the automation business, for me, subjects like this really bring focus to where the journey takes us in our careers. I remember my first exposure to motion control and the electrical cabinets I worked with were big enough to step inside. Most times, the huge enclosures were to dissipate the heat generated by the components inside and not necessarily due to the number of components needed to control the process.
Many environments do not allow for panel cooling that involves direct exchange of air from outside the enclosure, so our only choice was to make the surface area of the cabinet big enough to count on the movement of air outside the enclosure to draw heat off the outside surface.
Awareness of the presence of a newer technology does not always translate into using that newer technology. Over the course of a career, we tend to develop good solutions that we fine-tune from project to project. We become comfortable with grabbing what become canned solutions to different parts of our new project, and this can lead to inadvertently sliding behind the times.
RICK RICE is a controls engineer at Crest Foods (www.crestfoods.com), a dry-foods manufacturing and packaging company in Ashton, Illinois.
MANY OPERATIONAL-TECHNOLOGY (OT) networks that are not on distributed control systems may not have server backups or any programmable-logic-controller (PLC) backups, and this puts business at risk.
Operations folks need to evaluate their data, substantiate the risk of a data loss to the business, understand the recovery options and timeframe and then decide on mitigation. Once those steps are done, the system should be tested periodically to make sure backups are usable for action.
First, it’s imperative to understand that OT data is centered around real-time data processing that monitors a process or control of physical devices. Picture electricity power transfers and schedules based on grid use. Perhaps there are scheduled transfers during peak hours; during low hours, electricity is put more toward cities based on loads. Or, for discrete manufacturing, picture pharmaceutical traceability or tracing product in a process for work in progress, which is used in every modern-day operation. Batch recipes or CNC program storage for bulk production can take stored data and load it to machines. Or it could be as simple as tracing shipping container locations, such as the 2017 cyber attack against Maersk that crippled the company in a short amount of time and hindered logistics schedules for various Maersk customers worldwide.
The time that data moves from the PLC into a register for uptake in a database is the time that there needs to be a reference to save that data to a backup device. Thus, if you have a machine with 12 stations and your customer requires traceability of, say, torque values, then one unit may have a minimum of 12 data points per build.
However, realistically, there would be more like 48 data points per build to go up under that register for the unit.
Now look at the production time. If a line makes 50 units per hour, then picture 50 units multiplied by 48 data points and multiplied by however many hours of production.
There needs to be a reference to save that data to a backup device.
This means that there are 28,800 data points for that line in a 12-hour period. What if you have five lines? Then there are 144,000 data points in 12 hours.
If the customer calls with a complaint, the ability to look up that data in a timely manner is imperative. This means understanding storage requirements.
It’s easy to see how IT and OT are related, and that IT infrastructure and the costs of terabytes is something to understand if machine builders are interfacing with plant processes that require traceability of material or assembly products. Thus, it would be recommended to have PLC software backups and an historian backup for the intermediate data going to the database. It would also be recommended to do a database backup.
What happens if a PLC or a hard drive fails, and all WIP data is lost? Is there a backup? What is the recovery plan?
Asset managers for PLCs should be implemented on the OT network; the HMI screens should be able to dump data read at the time of the action into a database, and that should be stored raw in an historian and then sorted in backups for database management. Historians have been the traditional word for this data repository, but today it could be a data lake, a data platform or a distribution dashboard. We even can store short-term data at the PLC level if we need an average and data changes might be stored in milliseconds, or at change on every machine cycle, or at different operations in the line.
Then there is the backup timing. This is where it’s important to take operations suggestions from the distributed-control-system side and spend the money on a backup device because physical duplicates allow hot swaps and time to keep producing while data is stored, or to recover if one of the machines fails.
Risk analysis of the types of failure a business may handle is based on the time to recover and threshold to mediate if a failure or cybersecurity attack occurs. The mediation of a failure depends on the structure and the processes put into operations.
Tobey Strauch is an independent principal industrial controls engineer.
Charles Palmer contributing editor
60 years of process variables
OVER THE PAST 60 years or so, advances in technology have significantly transformed the construction and functionality of measurement sensors in industry.
Head-mounted temperature converters have become smart and can accommodate two different sensors either for verification or for primary-unit-failure occurrences.
In the industrial measurement of level, however, we have seen significant advances particularly in the use of radar and laser technologies.
In the case of the radar, where the frequency of the wave determines the angle or spread of the beam—the first industrial units used beam frequencies from 6 GHz to 10 GHz—we see the latest 80 GHz units, due to the extremely narrow beam, are capable of measuring even down a pipe of small dimensions. In the case of lasers, their ultra- high-precision accuracy and stability makes them an ideal method for critical applications.
which operate at a temperature of 700 °C and require fairly frequent calibration, to the application of tuned laser diode technology, whereby any gas exiting the boiler stack, such as oxygen, carbon dioxide and many others, each having its own distinctive frequency, can be measured.
We have seen significant advances particularly in the use of radar and laser technologies.
Laser technology is also employed in the oil-and-gas industry in the form of a ground-based laser remote sensing system, such as light detection and ranging (LiDAR) that has been developed for continuous and real-time monitoring of atmospheric emissions from an oil refinery located hundreds of meters from the instrument. By using lasers mounted at different angles to the stack, 360° circumferential, the system is able to perform 3D scanning and profiling around the emission point. The method can be used in real-time monitoring of industrial aerosol emissions and in the control of industrial processes.
We have seen major changes with the original magnetic flowmeter having advanced from a four-wire dc device to a single-pair, dual-frequency unit that displays higher accuracies at both low and high flowrates. Clamp-on ultrasonic flowmeters have also advanced with the latest technology and display far higher accuracies than were previously accomplished. Lasers are now also available for the measurement of velocities, flow, in open-channel applications. This is achieved through the application of non-contact laser Doppler velocimetry (LDV) technology.
In terms of pressure measurement, the technology has advanced from capacitance differential-pressure (DP) transmitter working-principle cells to the very latest solid-state piezoresistive devices which produce amazingly higher accuracies and show almost zero drift in terms of calibration over many years. Digital pressure gauges, with or without wireless transmission, have become the norm, and the increase in accuracy over the older generation of Bourdon tube gauges is remarkable.
When it comes to analytical measurements and the sensing thereof, the determination of excess oxygen in a boiler stack, for instance, has progressed from the zirconia probes,
Even in the realm of pH measurement, the latest electrodes are basically “smart” and capable of being buffered and then stored for immediate installation when necessary. This is a massive step, in light of all the requirements previously necessary when changing an industrial pH sensor in the field.
Finally, imagine accepting a job as instrument engineer at a factory in the late 1960s to find that the level indicator in the mixed-juice tank was a wooden pole, vertically floating in a pipe and painted with red and white stripes; depending on the number protruding from the top of the tank, the process operator, located within line of sight, would open and close a large handwheel-operated valve accordingly to maintain some degree of level control.
When I installed a flange-mounted level transmitter on the tank, with controller and control valve with I/P converter, everyone said I was crazy and that it would never work. Well, it’s still working there today in the very factory that I spent 13 years automating virtually every department.
Charles Palmer is a process control specialist and lecturer at Charles Palmer Consulting (CPC). Contact him at charles101143@gmail.com.
How IO-Link changed data communication
What makes IO-Link fieldbus-independent and integrable with different protocols?
by Mike Bacidore, editor-in-chief
ELEVEN PANELISTS ANSWERED questions about IO-Link. Raj Rajendra is product consultant/manager, Distributed IO & Logic Controller, at Siemens. Zin May Thant is global marketing manager, distributed I/O portfolio, and Todd Bissell is strategic marketing manager, sensing, safety and industrial control portfolio, at Rockwell Automation. Jason Haldeman is senior product specialist—I/O and gateways, at Phoenix Contact. Franz Ferre is product manager—controllers at Omron Automation. Eric Halvorson is senior marketing technology manager—automation & control for DigiKey. Jill Oertel is product line manager, sensors, at Carlo Gavazzi. At the time of this interview, Ed Polzin was product manager, controls, at Bosch Rexroth. Azad Jafari is I/O product manager at Beckhoff Automation. Shishir Rege is product marketing manager—networking at Balluff. Chris Kregoski is an integration specialist at AutomationDirect. He spent nearly a decade as the owner of Woodwest Controls, a small system integrator, servicing start-ups in malting, brewing, distilling and water treatment industries.
What are the advantages of IO-Link in terms of diagnostics?
Chris Kregoski, integration specialist, AutomationDirect : In addition to the large amount of process data available cyclically, faults can be identified easily through diagnostic information messages. This includes device faults, such as memory or processor failures, or process faults like empty pipe detection. Comprehensive diagnostics reporting increases overall system reliability and boosts customer confidence in the process as a whole.
Shishir Rege , product marketing manager—networking, Balluff : IO-Link is a data communication instead of a signal communication, so the devices, such as measurement sensors, are not limited to providing 4-20 mA or 0-10 V signal for the measurement units. Instead, the actual engineering units can be transferred directly from
the sensors. Having data communication onboard, sensors and other IO-Link devices also can communicate more information about the health of the sensor/device, as well as information about the ambience that the sensor resides in. IO-Link unleashes the sensor’s potential to not be limited to the process, but instead could help overall effectiveness of the automation and applications on the factory floor. The added diagnostics help monitor the condition of the environment or common faults that typically occur with the sensor. These added diagnostics help reduce the downtime on the line or the plant floors.
Azad Jafari, I/O product manager, Beckhoff Automation : IO-Link enables continuous monitoring of connected devices, allowing for real-time diagnostics and status updates. This helps in identifying potential issues before they escalate. And like EtherCAT, IO-Link can detect and report various types of errors, such as communication failures or device malfunctions, facilitating fast troubleshooting and scheduled maintenance. With real-time diagnostics, maintenance personnel can address issues promptly, reducing system downtime and improving overall productivity. IO-Link’s remote parameterization and configuration of devices enables adjustments without the need for physical access, which can also save engineering time and costs.
Ed Polzin, product manager, controls, Bosch Rexroth : IO-Link devices provide real-time diagnostic information, allowing for quick identification and resolution of issues. IO-Link devices can provide detailed diagnostic information, such as device status, temperature and operating conditions, allowing for more streamlined system troubleshooting, diagnosis and issue resolution. With the detailed diagnostic information provided by IO-Link devices, predictive maintenance can also be implemented, reducing downtime and increasing overall equipment effectiveness (OEE).
machine input
Jill Oertel, product line manager, sensors, Carlo Gavazzi: IO-Link enabled devices can exchange, collect and analyze data and convert it into actionable information. This is a critical piece toward an Industry 4.0 journey by accessing critical data from the automation edge—lowest field level—and translating it into valuable information. The goal is to make smarter decisions faster. To do that, users need system transparency and access to the right data at the right time. Many IO-Link sensors can provide the number of operating hours, number of power cycles, max and min internal temperature, detection counter and download counter. Even further, some IO-Link sensors provide events or alarms for temperature, dust/ debris buildup, condensation and misalignment. Communicating this information to a higher level allows users to plan maintenance prior to failure and see insights across multiple manufacturing lines or even plants. These insights can be differentiating for uptime and efficiency.
Eric Halvorson, senior marketing technology manager—automation & control, DigiKey : In terms of diagnostics, IO-Link provides users with both real-time data and historical data. Combining that information, users can see each individual sensor and not only look at the data it is providing but also how well the sensor is performing. This information lets users know when a sensor may be failing and allows them to quickly diagnose the problem, repair or replace the sensor and significantly reduce downtime.
Franz Ferre, product manager—controllers, Omron Automation : IO-link has three main advantages for diagnostics.
First, regarding the IO-Link device itself, is it functioning properly, is the device starting to show wear, and will it need replacement soon? When IO-Link is installed, it is possible for the system to check itself compared to its expected performance and if there is a difference, a fault can be triggered.
Second, regarding wiring, an IO-Link system can detect wiring faults and pinpoint where they are in the system. In a traditional system it could take minutes to hours to pinpoint which circuit is having a fault or if there is fault present or not.
Third, IO-Link can help reduce troubleshooting during device replacement. This is because IO-Link can save all the
optimal settings for each device in a system. So, if a device does fail, the operator can simply just replace the device and not have to worry about adjusting any of the settings to get the machine running again. This does require the programmer to save the settings in the IO-Link master so that they can be automatically restored. This feature is called automatic device replacement, or backup and restore, depending on manufacturer.
Jason Haldeman, senior product specialist—I/O and gateways, Phoenix Contact : Diagnostics is a key feature that drove the development of IO-Link for sensor communications. Before IO-link, sensor diagnostics readable via the control system were nonexistent. Sensors had internal diagnostics but were only able to display this locally at the sensor. IO-Link changed this and now allows the IO-Link I/O module to read diagnostics and back up the sensor configuration for fast sensor replacement.
Zin May Thant, global marketing manager, distributed I/O portfolio, Rockwell Automation : Leveraging IO-Link technology allows utilization of a plant or machine’s greatest asset—real-time data—to improve throughput and overall equipment effectiveness (OEE).
With more capacity than standard digital or analog signals, IO-Link offers more advanced diagnostics data beyond basic process data to help monitor the status and health of the IO-Link-enabled devices. The kind of diagnostics data that can be retrieved depends on the device manufacturer. This data could include diagnostics event-logging that allows users to perform predictive maintenance while enabling them to identify the issue and troubleshoot faster, reducing downtime. The IO-Link signal quality could also be monitored, which helps determine the validity of the values read.
Raj Rajendra, product consultant/manager, Distributed IO & Logic Controller, Siemens : Maintenance places increasingly strict demands on the quantity and level of training of personnel. IO-Link simplifies equipment replacement, reduces maintenance costs through better diagnostics and prevents downtimes. Conveniently run diagnostics information is sent over the same line as the process data without the need for additional cable lines.
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How does IO-Link handle multi-sensor devices? Can I configure and access data from individual sensors within a single IO-Link device?
Chris Kregoski, integration specialist, AutomationDirect : Multiple sensor readings from a single sensor are updated cyclically into the process data communicated from an IO-Link device to an IO-Link master and then on to a host like a programmable logic controller (PLC). This process data can vary in length.
Shishir Rege, product marketing manager—networking, Balluff : IO-Link made it possible to have multi-functional sensors that can be configured for a variety of operations. For example, an IO-Link smart photoelectric sensor can be configured for background suppression, diffuse or retro-reflective mode of operation ensuring various types of materials can be detected with the single sensor instead of having to implement multiple sensors. The same photoeye could also offer condition monitoring features such as monitoring of vibration, temperature or humidity, as well. As the IO-Link device provides data communication, it allows for configuring several different parameters of the smart sensors.
Azad Jafari, I/O product manager, Beckhoff Automation : IO-Link supports device profiles that define the structure and functionality of multi-sensor devices, enabling the integration and management of multiple sensors within a single device. Each sensor can be parameterized for settings such as measurement range, sampling rate and thresholds.
IO-Link allows both cyclic—regularly scheduled—and acyclic—on-demand—communication for continuous monitoring and specific data retrieval or configuration commands. Multi-sensor devices use sub-addresses to identify and access each sensor, with the IO-Link master handling data requests and command communication. These devices can store multiple sets of parameters for easy retrieval and modification. Detailed diagnostic information for each sensor aids in performance monitoring and maintenance.
Ed Polzin, product manager, controls, Bosch Rexroth : An IO-Link master will typically support four, eight or 16 device inputs. As an example, consider a
variable-frequency drive (VFD) with a set of digital and analog inputs available locally on the VFD. The ability of the IO-Link master to handle the IO-Link data structure of the example device will depend on the memory space in the master for the device description files, which can vary from manufacturer to manufacturer.
Jill Oertel, product line manager, sensors, Carlo Gavazzi: Yes. Users can configure and access individual sensors, even if the sensors are the same part number, even if the sensors are different technologies, even if they are using the same IO-Link master. Configuring sensors is extremely simplified with IO-Link. During replacement, the IO-Link master will automatically check if the new connected device is the right part number and reconfigure it with the same parameters as the previous device.
Eric Halvorson, senior marketing technology manager—automation & control, DigiKey : One great advantage of IO-Link is the ability to see, configure and monitor each device separately. It is a point-to-point protocol rather than a fieldbus protocol. This means each sensor or device is set up individually and assigned an I/O device description (IODD) file. This helps to identify the device and its capabilities. Another great feature is that this can be done remotely rather than on-site at the sensor or device. Beyond that, if a sensor needs to be replaced, there is a feature known as auto-device replacement that imports the data and settings of the old sensor to the new sensor, reducing replacement time and potential downtime for the line.
Franz Ferre, product manager—controllers, Omron Automation: IO-link utilizes what is called an IO-Link master. An IO-Link master is basically a hub that multiple IO-Link sensors and devices can be plugged into. Then the IO-Link master consolidates all the data and communication of the IO-Link devices that are connected to it. The IO-Link master then communications all this consolidated data back to the controller/programmable logic controller (PLC)/ industrial PC (IPC) via a single network cable.
Todd Bissell, strategic marketing manager, sensing, safety and industrial control portfolio, Rockwell Automation: If you have a multi-sensor IO-Link-enabled device, you should be able to configure and access data from the individual sensors. This is possible due to the device profile
that would define how data from the various sensors are structured for transmission. Users can refer to the I/O device description (IODD) file of the multi-sensor device to determine how to read and write data for individual sensors.
What cable topology options are available with IO-Link? Can I use daisy-chain connections, or is a dedicated point-to-point connection required for each device?
Jason Haldeman, senior product specialist—I/O and gateways, Phoenix Contact: IO-Link is a point-to-point communications network and was not developed to be daisy-chained. The idea behind IO-Link was to change nothing about the way sensors were wired to the I/O module and find a way to talk to the sensor. Typical sensors need three wires: power, ground and signal. IO-Link simply took the signal line and turned it into a new communication protocol that could be turned on and off as needed. So, in the specification, IO-Link at a minimum simply requires a non-shielded three-wire sensor cable but can also support five-wire cables if additional signal or power lines are needed.
Chris Kregoski, integration specialist, AutomationDirect : IO-Link devices can’t be daisy-chained, so a dedicated cable will be required between each IO-Link device and the associated master. An IO-Link master can attach to a number of IO-Link devices, and masters can be daisy-chained with EtherNet/IP communications and power cables, which reduces field cabling and installation costs on a machine.
Shishir Rege, product marketing manager—networking, Balluff : IO-Link is a point-to-point communication. Daisy chaining is not possible with IO-Link. Each IO-Link device connects directly to an individual master/ gateway port. Balluff offers devices that have expansion ports to offer modularity of the device space, but it is not to be confused with daisy chaining.
Azad Jafari, I/O product manager, Beckhoff Automation : IO-Link primarily uses a point-to-point connection where each device connects directly to an IO-Link master port for reliable communication and individual diagnostics. In a star topology, multiple devices connect to a central IO-Link master. IO-Link can also
integrate with other fieldbus systems like EtherCAT, maintaining point-to-point connections to the master within a larger network.
Ed Polzin, product manager, controls, Bosch Rexroth : IO-Link supports point-to-point connections, where each device is connected directly to the IO-Link master or hub using its own dedicated cable. This configuration may be preferred in certain applications where individual device isolation or specific wiring requirements are necessary.
It is also possible to daisy-chain IO-Link masters in a system. This allows for the optimization of cabling based on the specific needs of the system, providing greater flexibility in system design and implementation.
Jill Oertel, product line manager, sensors, Carlo Gavazzi : When using IO-Link sensors with an IO-Link master, point-to-point connection is required to the IO-Link master in order to receive sensor-specific events and information. However, many users are not yet ready to implement an entire IO-Link system. Some sensor manufacturers offer smart functions, which provide an option somewhere in between simple discrete sensors and a full IO-Link environment. Functions such as counters, speed and length measurement and pattern recognition allow computing to happen in the sensor, which is faster and reduces the burden on the programmable logic controller (PLC). Some of these functions require a “trigger” sensor to be daisy-chained with the IO-Link sensors.
Eric Halvorson, senior marketing technology manager—automation & control, DigiKey : Since IO-Link is a point-to-point protocol, each device does need its own connection to the IO-Link Master to enable communication, as well as its own unique IODD. Cabling topology consists of M5, M8 or M12 connectors designed for IO-Link-enabled devices.
Franz Ferre, product manager—controllers, Omron Automation : IO-Link is point to point. So, for each IO-Link device, a dedicated cable is required to connect the IO-Link device to the IO-Link master. IO-Link utilizes either four-pin or five-pin cables, typically M12. Four-pin M12, also known as Type A, is the most common.
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Type B, which utilizes five pins, has an extra pin available to provide further power for larger devices such as motors.
How does IO-Link integrate with different fieldbus protocols commonly used in automation systems?
Todd Bissell, strategic marketing manager, sensing, safety and industrial control portfolio, Rockwell
Automation : IO-Link is fieldbus-independent and can integrate with different fieldbus protocols via the IO-Link master. The IO-Link master, being the gateway between IO-Link enabled devices and the controller, will be the device that is connected to the controller via the corresponding fieldbus protocols of the control system, for example, EtherNet/IP. When the main network is EtherNet/IP, IO-Link is geared toward providing an Ethernet-like performance and user experience for field devices where direct Ethernet connection is too costly or bulky. IO-Link allows the connection of simpler field devices and more complex Ethernet/fieldbus-enabled products to be mixed seamlessly across a control system.
Jason Haldeman, senior product specialist—I/O and gateways, Phoenix Contact : When looking at IO-Link master, it helps to think of it as just a smart I/O module. On the I/O side, we have the IO-Link communications providing the three key features: sensor data, sensor configuration and sensor diagnostics. On the fieldbus side, the module views the programmable logic controller (PLC) as an I/O module with a lot more data. For example, a traditional Ethernet I/O module with eight digital channels may transmit 2-4 bytes of data to the PLC. Eight bits are for I/O signals, and the rest may be some simple diagnostics bits. For an eight-channel IO-Link master I/O module, each channel can transmit up to 32 bytes plus another 9 bytes for alarm data. So, eight channels may transmit up to 328 bytes of data to the PLC. This extra data can be overwhelming to the programmer, but, in the end, it’s all the data you will ever need. You may only need a few bytes to run the application, and the rest can be funneled through the PLC up to a human-machine interface (HMI) or cloud.
Chris Kregoski, integration specialist, AutomationDirect : One IO-Link master we offer, for example, communicates using EtherNet/IP. Other IO-Link masters are
available with a variety of fieldbus options, such as Modbus TCP, Profinet and AS-i. The user or designer simply needs to choose an IO-Link master that is compatible with the host device or controller.
Shishir Rege, product marketing manager—networking, Balluff : IO-Link is a device level technology and not a control level technology. The fieldbus protocols such as EtherCAT, EtherNet\IP and Profinet are control level communication technologies. The IO-Link gateway module acts as an aggregator to collect the data from IO-Link devices and transfers that data over the fieldbus protocols to programmable logic controller (PLC) or controller at the control level.
Azad Jafari, I/O product manager, Beckhoff Automation : IO-Link integrates with fieldbus protocols like EtherCAT through IO-Link masters, which act as gateways between IO-Link devices and the main fieldbus network. The IO-Link master collects data from connected devices and translates it into the fieldbus protocol format, transmitting it to the central controller or PLC.
This integration allows for centralized configuration, diagnostics and reliable communication.
Standardized interfaces ensure compatibility and seamless setup, combining IO-Link’s detailed device-level communication with the high-speed, real-time data transfer of fieldbus networks like EtherCAT.
Ed Polzin, product manager, controls, Bosch Rexroth : IO-Link integrates with different fieldbus protocols using IO-Link masters. IO-Link masters act as gateways, allowing communication between the IO-Link devices and the fieldbus network.
The IO-Link master translates the IO-Link device data into the format required by the specific fieldbus protocol. IO-Link master integration with different fieldbus protocols provides flexibility and compatibility, allowing for the incorporation of IO-Link devices into a wide range of automation systems and networks.
Jill Oertel, product line manager, sensors, Carlo Gavazzi: An IO-Link master is required to translate the IO-Link communication protocol to a fieldbus. These IO-Link masters are offered with a variety of ports and sizes—DIN rail-mountable, machine-mountable. Additionally, some
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original equipment manufacturers are excited about the cloud/edge capabilities offered by IO-Link. Fieldbus
IssueofFrequency:Bi-monthly
communication can be skipped altogether if the IO-Link master offers an onboard OPC UA server.
Eric Halvorson, senior marketing technology manager—automation & control, DigiKey : Due to its fieldbus neutrality, the IO-Link protocol works very well with just about any fieldbus, including Profibus, Profinet, EtherCAT, SeRCoS, Modbus and many others. Each IO-Link device has its own IODD, making this neutrality possible.
Franz Ferre, product manager— controllers, Omron Automation : The IO-Link master acts as a gateway, or a converter, between IO-Link and the other commonly used protocols. The IO-Link master will typically have one or two network ports that support either one or multiple standard fieldbus protocols. The most common protocols are EtherNetIP, EtherCAT and ProfiNet. Nowadays, there are IO-Link masters for most of the known field networks.
What are the cost implications of implementing IO-Link compared to traditional wiring methods? Is the upfront cost of IO-Link devices offset by long-term benefits like reduced wiring complexity and improved diagnostics?
Franz Ferre, product manager—controllers, Omron Automation: It really depends on the system, what kind of IO-Link devices are desired and how far the devices will be mounted away from the main control cabinet. When considering the cost of IO-Link, it is best to consider all the costs involved. For a standard system, this will include the cabling, the costs to have a panel built by a
certified panel builder, the costs of analog devices and analog IO cards. For an IO-Link system, cabling costs are usually reduced, as well as panel-building costs, and IO-Link can replace analog devices in many systems furthering the total cost. Oftentimes, the total cost is roughly the same between a standard system and an IO-Link system.
The largest upfront cost will be in engineering. Engineering will need to learn how to implement IO-Link in a way that maximizes all the benefits. This can take some time for them to create templates and program function blocks. Once the engineering has spent the upfront time, they will find that there are many tools with IO-Link that can reduce their programming efforts.
Jason Haldeman, senior product specialist—I/O and gateways, Phoenix Contact : First, if you look from a component cost, moving to IO-Link has a minimal increase in cost. If you also factor in converting analog sensors to IO-Link, the cost will be reduced through the elimination of analog-to-digital (AD) converters. But, like any newer technology, there is an engineering cost that keeps the cost a little higher until the market embraces the technology.
From the customer side, the minimal cost increase can easily be absorbed through the features IO-Link provides, like fast sensor replacement, because the I/O modules— IO-Link master—can back up the sensor configuration. Additionally, the sensor can provide precise diagnostics to prewarn its end of life, allowing the device to be replaced on normal downtime vs. system fault.
Zin May Thant, global marketing manager, distributed I/O portfolio, Rockwell Automation : Implementing IO-Link requires procuring not just IO-Link-enabled devices but also IO-Link masters and peripherals such as cables. The technology and product training for your workforce also require some additional upfront investment.
Despite the upfront costs, IO-Link is a worthwhile investment that can be offset by long-term benefits such as reduced wiring complexity and improved diagnostics. While avoiding a costly and unplanned downtime situation alone, with the diagnostics data available, can justify the investment in an IO-Link solution, there are many other benefits. Another plus point for IO-Link is the ease of configuration and replacement, which allows flexibility in making multiple device parameter changes based on application
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requirements and switching out devices without the need for manual reconfiguration. This will help alleviate any concerns about the lack of trained personnel on-site if there is a device failure.
Raj Rajendra, product consultant/manager, Distributed IO & Logic Controller, Siemens : The key benefit of IO-Link is it saves on installation costs. A three-wire cable without shielding can connect to a device and read and write many bytes of data in real time. In addition, parameter data, alarm and event are available using acyclic communication. Devices can be replaced without the need for parameterizing as data is already stored in the master or the controller.
Chris Kregoski, integration specialist, AutomationDirect : Wiring IO-Link sensors typically requires less cabling than traditional sensors, as these connections are aggregated at the IO-Link master that can
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be installed in close proximity to the sensors themselves. Therefore, the longer run consists of a single power/ communications cable set. Daisy-chaining multiple IO-Link masters, as needed, can further improve the cost advantage of IO-Link. Because many IO-Link devices offer multiple types of sensor data at once, multiple traditional sensors can be replaced by a single IO-Link sensor, adding further savings in cabling, plumbing, and vessel penetrations.
Shishir Rege, product marketing manager—networking, Balluff : IO-Link has been in the field for more than 14 years and has gained popularity because of the cable standardization and reduced wiring. Additionally, IO-Link providing data communication on the same cable that was used for discrete I/O also enables today’s automation to be smart and more effective. Traditional wiring requires much manual labor and has high propensity for mistakes and maintenance. The long-term cost is much higher while the machine build cost is also much higher with traditional wiring.
Most IO-Link implementations use M12 connectors and either single-ended or double-ended cables that significantly reduce wiring errors. Added diagnostics with IO-Link also help tremendously with incorrect wiring and for troubleshooting problems in the field.
Due to the popularity and adoption of IO-Link, there are hardly any add-on costs when switching from traditional wiring methods to IO-Link. In fact, most installations noticed considerable cost savings with IO-Link.
Azad Jafari, I/O product manager, Beckhoff Automation : While the initial investment in IO-Link technology may be higher, the long-term savings from reduced wiring complexity, improved diagnostics, simplified maintenance and increased productivity often outweigh these costs. The overall cost-effectiveness of an IO-Link implementation depends on the specific application and scale of the overall automation system, but many users find the long-term benefits justify the initial expenditure.
Ed Polzin, product manager, controls, Bosch Rexroth : The implementation of IO-Link may involve higher upfront costs compared to traditional wiring methods due to the need for IO-Link masters, cabling and IO-Link-compatible devices. However, the easy configurability and replacement of devices may offset those costs in the
long-term. IO-Link devices are easily configurable and can be reprogrammed for different tasks, providing flexibility and adaptability in changing production environments. This can lead to cost savings by reducing the need for additional hardware and minimizing downtime during reconfiguration. Further, there is a large array of IO-Link manufacturers and devices to choose from, allowing optimization for the most appropriate and available option for the system.
Jill Oertel, product line manager, sensors, Carlo Gavazzi : A cost calculation really depends on each individual application. A healthy return on investment (ROI) can be seen for situations with excessive wiring, especially considering installation time. Although most IO-Link sensors are similarly priced to sensors without IO-Link, the initial cost of adding an IO-Link master can be significant. However, the long-term costs need to be considered, as well; reduced downtime due to preventive maintenance, ease of replacement and system transparency down to the edge—lowest field level—provides more data for better decisions. The ROI for IO-Link is easily justifiable for applications when downtime is extremely costly, typically due to expensive scrap or high-speed manufacturing in consumer-goods manufacturing, such as feminine products or diapers, printing/labeling and plastic/rubber injection molding.
Eric Halvorson, senior marketing technology manager—automation & control, DigiKey : Due to the simplicity of the wiring required by IO-Link devices, the cost savings are great. Time to wire is reduced significantly since you are no longer required to utilize three-wire standard cabling with multiple parallel wiring. Additionally, IO-Link no longer requires shielded cable for analog signals. Instead, it uses standard sensor cables such as M8s or M12s.
Anything else that you’d like to add about IO-Link?
Eric Halvorson, senior marketing technology manager—automation & control, DigiKey: Adoption of IO-Link by new users can be time-consuming. There is a learning curve to its overall incorporation. However, despite these concerns, the level of functionality gained from employing the technology, coupled with the overall cost savings, makes
IO-Link a great option to enable communication with every aspect of your automation application.
Raj Rajendra, product consultant/ manager, Distributed IO & Logic Controller, Siemens: IO-Link is an open standard adopted by more than 100 vendors. IO-Link provides a significant advantage in data accessibility with implications across systems. Access to sensor-level data facilitates smooth system operation, simplifies device replacement and enables optimized machine maintenance schedules, leading to cost savings and reduced machine downtime.
Franz Ferre, product manager— controllers, Omron Automation : In the past, IO-link specifications have often been driven by the end user. Recently more original equipment manufacturers (OEMs) and system integrators are starting to implement IO-Link more. This is because they can be more confident in offering machines and services with reduced maintenance requirements for their end customers. Also, with a properly implemented IO-Link system, the amount of customer technical support will also be reduced.
The amount of installed IO-Link devices has been growing on an exponential curve, and the number of manufacturers offering IO-Link devices and solutions has also greatly increased.
Zin May Thant, global marketing manager, distributed I/O portfolio, Rockwell Automation : To build smart machines that drive efficiency and competitiveness, you need more actionable, useful data. Accessing this data will be easier
with IO-Link technology. Being fieldbus-agnostic, there are also fewer barriers in implementing IO-Link. According to several industry reports, it is projected that IO-Link will see exponential growth over the next 10 years at double digits compound annual growth rate (CAGR), driven by the need for simplification, increased flexibility and scalability in manufacturing.
Ed Polzin, product manager, controls, Bosch Rexroth : As industries continue to embrace Industry 4.0 and the Industrial Internet of Things (IIoT), IO-Link capabilities align with the need for smart, connected devices and
systems. Its integration with higherlevel control systems and compatibility with existing fieldbus networks make it an asset for modernizing and optimizing industrial processes. Overall, IO-Link’s combination of advanced functionality, flexibility and long-term cost benefits positions it as a key technology for enhancing automation and control systems in various industrial settings.
Shishir Rege, product marketing manager—networking, Balluff: IO-Link as a technology is evolving at a rapid pace. IO-Link wireless technology offers standardization of wireless communication and enhances functionality of already
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familiar IO-Link technology. The recent addition of IO-Link wireless and upcoming products on IO-Link Safety are changing the way automation is done today. IO-Link not only adds benefits for machine builders in terms of faster machine builds, but adds value throughout the life-cycles of the machine well into the maintenance mode.
Azad Jafari, I/O product manager, Beckhoff Automation : IO-Link integration with EtherCAT enhances automation systems by combining detailed device-level communication and diagnostics of IO-Link with the high-speed, real-time capabilities of EtherCAT for highly efficient data transfer and system management. Whether engineers require a field-mounted IO-Link gateway, a standard DIN rail mounted option or even a pluggable terminal to reduce wiring complexity, they often find that flexible solutions help future-proof their applications. They can build the overall machine or system using fast EtherCAT and PC-based control and then add or update sensors later as the project evolves using IO-Link.
Tell us about one of your organization’s stateof-the-art IO-Link offerings.
Todd Bissell, strategic marketing manager, sensing, safety and industrial control portfolio, Rockwell Automation: Rockwell Automation is constantly expanding its line of smart, IO-Link enabled products, which include sensors, masters, hubs, tower lights and electronic circuit protection.
The ArmorBlock 5000 IO-Link master blocks are the latest IO-Link master offerings from Rockwell Automation. The product was released in the first half of 2023 and is available in three power variants for various industry and application needs. The IO-Link master block comes with IO-Link Class A and Class B ports, expanding the variety of potential IO-Linkenabled devices that users can use. Its highly integrated IOLink capability provides an improved experience of integrating IO-Link enabled devices with Allen-Bradley controllers. The block also supports digital inputs and outputs, enabling a highly flexible and configurable solution to achieve the users’ desired business outcomes.
Jason Haldeman, senior product specialist—I/O and gateways, Phoenix Contact : The TRIO Power 24 V power supply from Phoenix Contact features a space-saving design, easy handling, and smart diagnostic functions.
Franz Ferre, product manager—controllers, Omron Automation : Omron’s new NXR Series IO-Link master is the first in the industry to offer “PC-less maintenance,” enabling customers to set up and replace the IO-Link master without special software or a PC connection. This allows anyone on staff to be able to perform maintenance, without any special tools or PC software.
Additionally, upfront engineering costs for implementing IO-Link can be drastically reduced when combining the NXR EtherCAT with an Omron NX or NJ Sysmac PLC. This is because Omron’s PLC software can automatically configure IO-Link devices into the PLC software. This saves engineers a lot of time by reducing the need to referencing multiple sensor manuals, and it can reduce manual data entry errors.
Raj Rajendra, product consultant/manager, Distributed IO & Logic Controller, Siemens : Siemens provides IO-Link masters for all our IO Series, and we also offer devices from our Factory Automation business and other business units of Siemens (Figure 1). The devices include IP65/67-rated IO, motor starters, relays, RFID tag readers, LED signal columns, switch boxes, power supplies and more. Our IO-Link master modules are MultiFieldbus (MFB) capable in that they can be configured for Profinet, Ethernet/IP and Modbus TCP with our free software tool MultiFieldbus Configuration Tool (MFCT). Both IP20 and IP65/67/69K-based master modules are offered for the customer to choose based on the application. The devices can be configured with ease with our free software S7-PCT tool. The tool can be standalone or be integrated in our software platform for automation, TIA Portal. Mapping of data from the devices can be done efficiently by the user data type created by the S7-PCT tool and using the UDT in TIA Portal to create a custom tag with all the real-time data
Figure 1: Siemens provides IO-Link masters for all of its IO Series and offers devices from its Factory Automation business.
from the device. Function calls are provided for reading and writing other parameter data to and from the device.
Ed Polzin, product manager, controls, Bosch Rexroth : CtrlX Automation is an open platform that provides all the building blocks to reduce time to market and minimize engineering costs. It also makes it easy to merge IT and OT applications for digitalization, connectivity and sustainability.
One of those building blocks is an IO-Link master, offering simple integration and commissioning of IO-Link devices into the ctrlX ecosystem. In addition, with ctrlX Automation World partners, support for IO-Link masters based on popular fieldbus protocols such as EtherCAT, Profinet and Ethernet/IP is simplified.
Jill Oertel, product line manager, sensors, Carlo Gavazzi: IO-Link is a critical piece of an Industry 4.0 journey by allowing visibility and communicating at the edge—lowest field level. However, many users are not yet ready to implement an entire IO-Link system. Configurable sensors offer value by reducing inventory to a single part number with the ability to customize not only the output and sensing range, but time delays, hysteresis, sensitivity and discrete alarms. This ability provides users another step on their automation journey without a major investment.
The configuration is possible using Carlo Gavazzi’s SCTL55 handheld IO-Link programmer (Figure 2). All IO-Link parameters from any IO-Link sensor and any manufacturer can be configured and saved.
Figure 2: Configurable sensors offer value by reducing inventory to a single part number with the ability to customize not only the output and sensing range, but time delays, hysteresis, sensitivity and discrete alarms. The configuration is possible using Carlo Gavazzi’s SCTL55 handheld IO-Link programmer.
Azad Jafari, I/O product manager, Beckhoff Automation : Beckhoff provides a wide verity of Class A or Class B IO-Link products. As an example, the EP62280022 IO-Link module allows connection of up to eight IO-Link devices, such as IO-Link box modules, actuators, sensors, or a mix of these (Figure 3). The machine-mounted EP6228-0022 serves as an intelligent interface between the
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Figure 3: IO-Link masters and devices/ hubs with an IP20 protection rating can be installed for use in control cabinets, and devices with an IP67 protection rating can be used for modular machine concepts with devices installed in the field.
(PHOTO COURTESY: BECKHOFF)
fieldbus level and the sensor, facilitating bidirectional exchange of parameterization information through the IO-Link connection. The configuration and parameterization of the IO-Link devices using service data can be performed via TwinCAT 3 automation software or the integrated IO-Link configuration tool.
In its default setting, the EP6228-0022 functions as an eight-channel input module at 24 Vdc. It communicates with the connected IO-Link devices, configures them, and adjusts their operating modes as needed. Each IO-Link port can also be used purely as an input or output.
The EL6224 IO-Link terminal from Beckhoff offers a DIN rail-mounted version of this functionality, while the EJ6224 variant condenses it further into a no-wire option that plugs directly into a printed circuit board (PCB). This ensures the terminals can be easily incorporated into the standard I/O segment in case field mounting isn’t necessary. Our modules also have variants that incorporate TwinSAFE technology, making them some of the only IO-Link masters on the market to integrate functional safety.
Chris Kregoski, integration specialist, AutomationDirect : AutomationDirect offers a large portfolio of IO-Link modules and field devices, including Stride and Murrelektronik IO-Link master and hub modules, photoelectric and proximity sensors, signal towers, flow and pressure transmitters, and much more.
The Endress+Hauser Picomag flow meter is an example of an advanced sensing device that leverages IO-Link to provide much more data than simply fluid flow. This sensor also supplies the temperature and conductivity measurements, as well as sensor status, all over a three-wire M12 connection.
and Kawasaki Robotics collaborate on CNC machine-tending shelf system
by Anna Townshend, managing editor
Hurco
HURCO’S CUSTOMERS SAID they would buy a new computernumerical-control (CNC) machine if Hurco could get them an operator. Manpower wasn’t in the company’s repertoire, but Hurco knew automation and robotics could help alleviate labor-force issues facing machine shops.
Hurco unveiled its robotic machine-tending shelf system in collaboration with Kawasaki Robotics. Aimed at highmix, low-volume manufacturers who don’t want to learn how to program a robot, the turnkey, no-code system will come out of the box designed and ready for the application.
Hurco manufactures CNC machines for a wide range of customers. While it does serve some large customers, its primary market is job shops with significant part changeover, and small- to medium-sized enterprises. “Our focus has been in providing technology that’s very simple to use and effective for programming and running the machine tools, and we’ve extended that to the machinetending automation, as well,” says Paul Gray, executive vice president of engineering, R&D and product development at Hurco.
In 2023, Hurco began discussions with Kawasaki about a collaboration, keyed on each company’s strengths: CNC machines and industrial robots. Development time was about a year from initial discussions to design cycles, including controls development to integrate the Kawasaki controller with the Hurco Job Manager software, which it had originally developed for collaborative robots. “We made a nice, seamless system that is conversationally driven, like our CNC control, to be able to control the robotic cell with the CNC machine and orchestrate the machine tending,” Gray says.
Before this project, Hurco had acquired ProCobots, a collaborative robot system integrator, designed to accelerate Hurco’s foray into automated machine tending.
When Hurco first introduced automation to its CNC customers, the company learned quickly that CNC operators are more focused on the machine, how to program and run it and cut quality parts, as that is the manufacturer’s primary business objective. “They really didn’t have the time and didn’t have the desire to learn how to program a robot controller and do all that work themselves. They needed
Figure 1: The modular shelf system was on display at IMTS in September and included a Kawasaki RS013N industrial robot.
something that would basically be as plug-and-play as possible, low connected to their CNC machine so that they can make parts,” Gray says. “When we deliver the machine, it’s basically plug-and-play with the machine.” The whole system includes not just the CNC machine, robot, shelves and pallets, but also the Ethernet connection between the robot, the software and the electrical and pneumatic connections.
“It’s been designed by our engineers who also design our machines, and also the software that drives all of this is designed, developed and executed by our software engineers, as well,” Gray says.
The Kawasaki system uses an industrial robot for a few reasons. “One is that we’re using this with a pallet-based system, which could be vices or straight pallets, where we mount parts directly to a pallet, and we’re using a cleat and single gripper system to pick up a pallet then load it into a
The turnkey, no-code system will come out of the box designed and ready for the application.
receiver in the CNC machine,” Gray says. “We’re not gripping parts directly. We’re gripping something that’s holding the part to load into the machine, and then return it to the shelf when it’s completed.” While collaborative robots have significantly increased payload as of late, this system didn’t need a lot of repositioning or tweaking, as the pallets are picked and reloaded consistently in the same array. Depending on the pallet, they weigh around 10 lb. Given a higher payload with pallets and parts and the longer reach needed for CNC machine tending, the industrial robot was the right choice, Gray says. It also allows for the system to scale even larger.
Hurco’s software Job Manager communicates with Hurco’s WinMax CNC Controls using Ethernet TCP/IP, and Hurco used the same software with the Kawasaki control to integrate and communicate with the Kawasaki controller. “There are robot programs running on the Kawasaki, which handle a lot of the robotic motion, but the orchestration of the whole cell of the CNC machine tool and the robot is conducted and driven by the Hurco Job Manager,” Gray adds. Set up is simple with Job Manager. Via a simple interface, operators select which pallets have which CNC programs
and where they are located in the shelving system, and queue up the appropriate jobs and press start. “It basically makes it a simple, conversational way to tell the system what I am going to make and how much of it I am going to make and where it is in the shelving system, and they’re not having to touch or deal with or program anything on the robot control or even the CNC machine, other than having the CNC program ready to cut the part,” Gray says.
The modular shelf system can be expanded to fit different size or quantity of parts or to handle higher payloads.
The system on display at IMTS in September, which sold at the show, included a Kawasaki RS013N industrial robot, but the system will work with any of Kawasaki’s industrial robots (Figure 1).
One key feature of the RS013N industrial robot is the integrated valves in drum three and an integrated I/O cable that goes up through the arm, which makes cable routing around the tool much simpler. “It reduces the amount of cable that the robot has to navigate around while going in and out of the machine, making the cell more compact and easier to integrate,” says Gilles Renard, application engineering team leader at Kawasaki Robotics.
Kawasaki, Renard says, is also very proud of its open architecture on the controller side. “People can use the robot and program it normally, or they can create their own system that controls the robot from an outside source. And that’s what allowed this interface to exist,” Renard says.
The system uses LiteVise grippers from 5th Axis. They have the same clamping force as standard vices, but, with an aluminum body, they are lighter for the robot to load.
“It’s designed exactly for pallet loading. We can screw on the zero-point clamp system directly to the bottom devices and the cleats for the gripper to hold, including the gripper that is mounted at the end of the robot,” Gray says.
The CNC system on display at IMTS was Hurco’s VM15Di CNC machine. “It’s a very nice machine because it has an inline spindle, which gives you a really good surface finish and very good acceleration/deceleration times, so it’s ideal for continually loading parts in and out and running automation,” Gray says.
When customers told Hurco, they would buy a machine, if they could get an operator, Hurco now has an answer for the labor-force decline. Where one operator is typically working four machines, setting up jobs on one and running parts to others, a machine-tending system alleviates some of that load, so operators can focus on less tedious tasks.
Make the connection
Cables, connectors and cordsets for equipment builders
Lutze Electronic control and signal cable
Lutze Electronic shielded or unshielded flexible control and signal cable is an industrial-grade multi-conductor cable. It is designed for use in machines and machine tools, plant cabling, HVAC technology, assembly/production lines, process instrumentation and industrial controls. These cables are 300 V rated and are third-party evaluated by EcoLab for resistance to cleaning agents and chemicals commonly used in food and beverage washdown procedures. The polyvinyl chloride (PVC) jacket is oil and sunlight-resistant, and this cable is power limited tray cable UL PLTC-rated for use with cable tray applications and AWM-rated for use in appliance wiring. The Lutze Electronic cable can be cut to length in 1-foot increments, with a 20-ft. minimum, starting at $0.74/ft.
to enable reliable connection. The portfolio of wire types ranges from PVC sheathings and PUR sheathings to POC sheathings specifically built for welding areas and PUR-O sheathings for outdoor applications. Additional cable features cover steel nuts, LEDs as operating and function indicators, cULus certifications and NAMUR suitability.
Pepperl+Fuchs / www.pepperl-fuchs.com
RS single-ended cordset
The 5-m cable from RS Pro features a straight M12 male connector to terminated end. The four-wire configuration allows for power and signal transmission and is suitable for applications including industrial automation systems, sensors, actuators, process control equipment and machinery. The green PVC jacket provides protec tion against wear and tear, designed to ensure long-lasting performance in demanding environments.
AutomationDirect / www.automationdirect.com
Pepperl+Fuchs M8/M12 sensor-actuator cables
Pepperl+Fuchs offers a portfolio of sensor-actuator cables for machine and plant operation. These sensor-actuator cables are available in many variations. The combination of different threading and wire types allows the user to match the application. The sensor-actuator cables with M8 and M12 connectors are designed to provide maximum service life. In addition to M8 and M12, the range of sensor-actuator cables contains numerous other common threading types such as ½-inch, 7/8-inch, M9 and M23. Gas-proof and gold-plated crimp connections are designed to increase vibration resistance and durability. Vibration-resistant knurled nuts are designed
RS / www.us.rs-online.com
Omron Automation XS2 waterand environment-resistive FA connectors
XS2 connectors with M12 threads from Omron Automation are compact FA connectors that meet IP67 requirements and ensure a 94V-0 fire-retardant rating. A wide array of connectors is designed to make a wiring system more modular and simplify maintenance. Connectors with cables and connector assemblies are available. Three types of connector assemblies include crimping, soldering and screw-on. Connectors with cables are UL-certified. XS2 is based on IEC61076-2-101 (IEC60947-5-2) and NECA 4202.
Omron Automation / automation.omron.com
product roundup
Murrelektronik MQ15 connector
The MQ15 is a connector designed to provide a secure connection for asynchronous and three-phase motors up to 7.5 kW. It is available in two versions: a 48 Vdc/20 A Type 2 version and a 600 Vdc/16 A Type 3 version, both equipped with a quarterturn locking mechanism. This IP67-rated and ULlisted product features cables with options for dragchain compatibility, high flexibility, flame-retardant properties, and oil/chemical resistance in PUR and TPE jackets, or chemical-resistant PVC jackets. The MQ15 portfolio also includes “h-couplers” for connection to multiple motors, “T-couplers” for daisy-chaining and fieldwirable installation accessories. With MQ15 receptacles, motors can be converted to plug-and-play. Motor integration is possible via the M20x1.5 thread.
Murrelektronik / www. murrelektronik.com
Belden M12 push pull connectors
IEC 61076-2-010 M12 push pull connectors from Belden are designed to guarantee secure contacting. The Lumberg Automation M12 Inner Push Pull Connectors feature a secure, fast-locking contacting method. The M12 Push Pull Connectors are optimal for use in harsh environments to prevent accidental disconnects. The M12 Push Pull Connector includes a portfolio of X-coded, D-coded and A-coded variants. The M12 Push Pull Connectors includes technology designed to ensure secure contact with out tools for torque. It eliminates the need to screw in connectors.
Belden / www.belden.com
Weidmuller USA PZ 2.5 crimping tool
Weidmuller USA’s PZ 2.5 S professional crimping tool for wire end ferrules is designed to be compact and ergonomic. In control cabinet construction, cables of the most diverse cross-sections are fitted with wire end ferrules. On average,
most of these connections are in a cross-section range of AWG 14 (2.5 mm2) and smaller. The small handle width and the opening angle, as well as the weight, is designed to make the crimping tool easy to use without incurring fatigue in the hand, wrist or arm. The tool features a length of 160 mm with a small grip width. Weighing around 10 oz, the tool is designed to be light to carry. The trapezoidal crimp in the cross-section range of AWG 26 to AWG 14 (0.14-2.5 mm2) complies with all current standards. The universal die is designed to prevent incorrect insertion and ensure error-free work.
Weidmuller USA / www.weidmuller.com
Binder USA M12 L-code for industrial automation
The M12 L-coded connector is designed to offer robust power distribution for industrial automation. It features 4+FE contacts with a rated current of 12 A/16 A at 63 Vdc. The 823 series includes straight and angled connectors with screw terminal connections and flanged connectors available with dip solder or stranded wires. Overmolded variants are designed to provide additional durability and ingress protection, while the Profinet-compatible version supports secure, high-speed data transmission, designed for demanding environments. The IP67 rating makes it usable in harsh environments.
Binder USA / www.binder-usa.com
Mencom single keyway quick-disconnect cordsets
Mencom’s Micro-DC (MDC) Series, also known as Microchange or M12, offers versatile quick-disconnect for industrial automation. These A-coded MDC connectors are designed for dc applications and come in two- to eight- and 12-pole configurations with various jacket materials. These rugged connectors are commonly used for sensors, actua-
tors, motors, switches, safety light curtains, mats and interlock switches. The M12 threading and euro-style color coding are designed to ensure reliable connections in demanding environments.
Galco / www.galco.com
Mencom power distribution (PMIN) series
The PMIN series is designed to offera plug-and-play offering for industrial motor, machine and power applications. These industrial circular connectors provide a quick-disconnect option for applications. The MINI power distribution series is UL-listed and offers IP69 protection. Available in three-pole and four-pole configurations, straight and right-angle orientations, these come with a full line of accessories, including adapter plugs, closure caps, plugs and integrated cable drops. Within the PMIN series, the 1-3/8-inch PMIN field-wirable connectors are designed to provide a quick-disconnect for installation and maintenance of equipment. Mencom’s right-angled version of the 1-3/8-inch field wirable connector has a profile that is lower than the typical bend radius needed for a straight cable. Additionally, it is designed to reduce undesirable cable strain caused by bending cables to fit into tight spaces.
Mencom / www.mencom.com
Phoenix Contact M12 Power for exposed cable runs
The TC-ER (Tray Cable—Exposed Run) PVC cables from Phoenix Contact can be routed outside of cable trays, which is designed to make them easier to install with more routing options. The power cables are compliant with the NEC Tap Rule. They are
UL-tested and approved under UL 2337 (E468743). The TCER cordsets are manufactured in the United States, using U.S.-sourced cables. They are part of Phoenix Contact’s Speedy Transaction program.
Phoenix Contact / www.phoenixcontact.com
Icotek cable entry frames for food and beverage
The icotek KEL-ER-BL is a split cable entry frame for cables with and without plugs. Depending on the size, cables with a diameter of 1 to 35 mm are inserted, sealed with IP65 and at the same time strain-relieved in accordance with DIN EN 62444. IP65 protection is achieved through the injected seal and the use of single grommets. The cable grommets are placed into compartments and are securely fixed into the frame during assembly. After the assembly is complete, the end cover is screwed on. The cable entry frame fits standard cut-outs for 10-, 16- and 24pin heavy-duty connectors. The cut-out size can be up to 46 mm instead of 36 mm, meaning that cables with larger connectors can also be routed.
icotek / www.icotek.com
Single-phase power supplies
Puls has 15 models of 24 Vdc field power supplies (FIEPOS) for decentralized power on machine mounting and IP65/67 applications. The six single-phase 100-240 Vac units are in addition to the nine three-phase 380-480 Vac models previously released. These power supplies include Puls’ reliability and efficiency standards. Flexibility in mounting options (DIN-rail or surface mount), connector styles and power range make FIEPOS adaptable for almost any application.
Puls / www.pulspower.us
real answers
How to assess ICS vulnerabilities
A CONTROL DESIGN reader writes: New industrial control system vulnerabilities are constantly popping up. It sometimes seems overwhelming. We’d like to be more proactive, but we’re integrating more robots/cobots into our workcells these days and keeping up with interoperability and controller interfaces is daunting enough. Is anyone else struggling to stay current? Are there guidelines or standards for cobot/machine integration and cybersecurity?
Answers
Vulnerability identification and remediation
The feeling of being overwhelmed is understandable and common across manufacturing facilities in the Americas. These teams are dealing with more frequent and severe cyberattacks, largely due to the increasing number of connected devices like software and control units on the factory floor. Alongside this, there’s pressure to boost production and cut costs, which can quickly become too much to handle. In such an environment, where operational technology and automation are essential for reducing costs, increasing production and minimizing cyber risks, it’s crucial to have a clear strategy. Although standards like International Electrotechnical Commission (IEC) 62443 provide valuable industry insights, we will focus on broader automation guidelines that make compliance easier and improve interoperability. By proactively addressing security, automation, collaborative robots (cobots) and operational technology in line with business objectives, companies can reduce costs, enhance efficiency and improve operational resilience, all of which lead to greater customer satisfaction. While every connected automation setup is different, three key factors increase the risk in its overall structure. These include the ability to identify vulnerabilities before and after deploying software, the broad impact of a security breach, and the speed at which a fix can be implemented before an attacker exploits the weakness. Although much has been discussed about these aspects, we suggest simplifying the architecture to manage these risks better, particularly through the use of all-in-one automation platforms. All-inone platforms, while they do not completely eliminate the risks found in more complex systems, do simplify man-
agement of these components. This simplification helps production teams develop and maintain better cybersecurity practices with greater confidence. To further strengthen these practices, we recommend working with industry experts. This partnership can help ensure that the solutions consider these factors during product design, commissioning and operation, leading to clearer production expectations and enhanced quality assurance.
All-in-one automation platforms are designed with a single integrated development environment at their core, where security is built in. This design meets the stringent resiliency and quality management requirements of even the most demanding environments. Managing a single software package that is compatible with various device and controller firmware versions is simpler than handling multiple systems from different suppliers. This consolidation facilitates quicker updates and reduces compatibility issues. The software also helps operators by showing device firmware versions, available updates, release notes and other critical information to keep production lines operating efficiently.
All-in-one automation platforms streamline the management of devices, reducing the burden and enhancing both reactive and proactive cyber hygiene. These platforms use globally recognized industrial protocols to ensure interoperability and integrate the security features of common industry standards, benefiting both customers and suppliers. Industry-standard protocols undergo extensive external scrutiny, making them easier to update and secure at scale compared to proprietary systems.
All-in-one platforms enhance security management by documenting and backing up program versions and allowing for version locks. Updates can be applied swiftly during scheduled maintenance across all machines or production lines, accompanied by necessary change management documentation. With features like automatic software updates, these platforms help teams maintain control over factory floor programs with minimal disruption. Embracing a security-first approach may require a cultural shift, but partnering with industry experts who support and update their automation software can instill confidence in production teams.
Well-implemented all-in-one platforms simplify the integration of cobots into factory settings. These platforms
support a wide range of firmware, reducing software management challenges and enhancing flexibility. They also ensure quick deployment of security updates, helping to close vulnerabilities more rapidly.
PATRICK DUNPHY head of cybersecurity / Omron
THOMAS KUCKHOFF product manager / Omron
Well-trained cybersecurity personnel
Many are struggling in this rapidly changing landscape of cybersecurity in the industrial automation control systems (IACS) community and operational technology (OT) environments. There are multiple factors contributing to a complex and difficult problem. Added to the inherent challenges created by all the growth and innovation changes that are happening in all kinds of industries, which creates a backlog of work for interoperability and cybersecurity checking and adapting, there is also the issue that the industry is going through a transition from isolated networking environments to more feature-rich connected environments.
But who is going to be doing all this extra work? Companies are tightening their belts and working to cut overhead. Asking for additional and very specialized workers who are seen as purely overhead is a tough sell and rarely popular. However, it is important to reframe the work that needs to be done into its true role. Cybersecurity isn’t overhead; it is risk mitigation and avoidance. These individuals prevent legal liability by taking the required due diligence for the environment and equipment to be protected. They prevent entire plants and businesses from being shut down due to a cyberattack, or worse, having to pay a large ransom to criminals to get production back up and running. Even with cyber insurance, the impact of one of these attacks can be devastating to entire industries.
While paying ransom through insurance may prevent profit loss by getting back to work, it also incentivizes those attacks and others to just do it again, but now with additional funding to create more sophisticated attacks. Well-funded hackers and malicious actors require even more security and defensive measures to keep out, costing much more for the entire industry in the long run. Well-trained and qualified cybersecurity personnel are not just industry best practice, they can make the difference between a company being an industry leader or losing millions of dollars in a matter of days.
Also, as IACS environments embrace many of the innovations and features from traditional information technol-
ogy (IT) environments, this opens up all the traditional attack paths that IT environments have been trying to defend for decades, but frequently without any of the defense structures. This change has caused an increase in malicious actors targeting these environments more than they have historically, because there are so many known vulnerabilities they can exploit. Trying to create a new “zero day” attack is much harder than doing an internet search for known vulnerabilities in a specific item, so any information an attacker can find out about your system can quickly lead to disaster, with almost no time to react. Without cybersecurity personnel working with designers and the day-to-day operations teams, implementing changes and protections against those known vulnerabilities, the risk of attack becomes more likely and more damaging very quickly. It is going to take a conscious investment to meet the challenges of today.
Currently, IEC 62443 is the only set of major cybersecurity standards for IACS type environments. This is true for a variety of industries, including robot- and cobot-filled manufacturing spaces. Many industries that do have regulations frequently have based their regulations off this set of standards, as well. Seeking to implement certification for your environment, or at least buying components that have some level of certification, can be a starting point for businesses that want to be better but just don’t know where to start.
I would also recommend asking suppliers or looking for suppliers who provide regular vulnerability notifications with mitigations and patches. These are proactive measures that can give focus to your efforts but are not a replacement for dedicated cybersecurity personnel who are trained and supported in looking to improve your security posture. Combining this with an emulated or fully digital testing environment to test patches and changes without taking down the actual production environment will help with the work of maintaining security without impacting day-to-day operations.
In a lot of ways cybersecurity is becoming more important than physical security because a connected environment is vulnerable to criminals worldwide, not just in your local area. And just like you wouldn’t leave the front door to your locations unlocked with no security guard, why are we not investing in security against an even larger group of attackers? We can see unlocked doors or holes in fences. We cannot see cybersecurity threats.
STEVE RAWLINS, SR., CISSP lead product cybersecurity officer, controls and software / Emerson Discrete Automation
real answers
Determining risk level acceptance
These comments hit on a big friction point in the cybersecurity community at the moment. Vulnerability fatigue is a major issue. At the moment, a lot of cybersecurity monitoring products really focus on asset management and vulnerability detection. The idea falls into the risk equation:
Risk = likelihood x Impact
But, if you break likelihood down a bit further, the likelihood of an incident comes down to threat x vulnerabilities:
Risk = business impact x vulnerabilities x threats
So, the idea is that, if you can reduce your vulnerabilities, you can reduce the risk of a cyber-related event. But this doesn’t take into account the amount of resource allocation necessary to actually address all the vulnerabilities. A lot of the OT security vendors provide service offerings to help address this resource problem, but for most end users, the budgets for this topic are limited.
So, there’s a new train of thought that chasing all the vulnerabilities is an exercise in futility. So, the idea is to look at the risk equation again. There are a couple of things to consider with the equation, as well. You can also reduce your risk by reducing the business impact of an event. So, if you build into your system fail-safes, that can mean the system is operated even when certain parts are affected by a cyberattack, then you’ve reduced the risk, as well. Another point is that vulnerabilities can be addressed in multiple ways. Patching is always the one that comes to mind, but using firewalls and endpoint protection can also “remove” vulnerabilities from affected systems by removing the attack vector.
Finally, the biggest point is that every organization needs to determine what its acceptable risk level is. You can’t always address all the risks because of limited resources. Every organization has to draw the line at: “This is acceptable for us.” That could be that they only patch biannually or that they don’t patch regularly, but instead put firewalls in place. That risk acceptance can change as the available resources change. Cybersecurity is a constantly changing and evaluated program.
If they are looking for reference stands, I’d start with the latest version of the National Institute of Standards and Technology (NIST) Cybersecurity Framework (CSF). It was released last year, and there’s new guidance on industrial control systems (ICS). The NIST CSF is a bit more approachable than IEC 62443, but if they want a more comprehensive program, then IEC 62443 is the way to go. In both of these standards, there is a section that outlines picking your tar-
get “security level.” This is essentially picking your benchmark for risk acceptance. What are you willing to do and not do based on the risks?
GRANT VANDEBRAKE
senior global networks system integration engineer / Phoenix Contact
VPN separation
Typical guidelines in the past had been to isolate machines into separate networks to limit the potential vulnerability plantwide by using virtual private networks (VPNs). VPNs help with encrypting data transmitted, as well as with authentication to make sure only authorized users can connect with the machine. VPNs help secure machines from outside access of the network. The same integration can be done locally on the machine, as well. This involves making sure each network module on the machine has the same encryption of the data, as well as authentication access to the module. Setting up correct authorization per user, as well as continuously monitoring the activity of each module, can help with local security as well. Finally, if there is a security breach, making sure there is a plan for backup and recovery of the data is important. This will help ensure everything gets back up and running quickly as smoothly as possible.
RANDY DANG product and application specialist / Balluff
OEM auxiliary services
This is a common issue with growing companies struggling to meet production goals while maintaining cybersecurity policies. The simple, but not easy, solution is utilizing original equipment manufacturer (OEM) or integrator services as an auxiliary to your current work force. Simple, as in the idea of contracting these services will free up your workforce to meet production goals. However, many of us know how difficult it is sometimes getting additional funding approved.
In the same manner you’re using cobots to augment your production force, OEM tech support can provide myriad maintenance services on the equipment they know best so your team can focus on output and quality control. The maintenance services offered by many OEM providers also include cybersecurity services, such as operating system (OS) and firmware patching, system hardening and secure integration between platforms.
One guideline for patch management within an OT network can be found in the International Society of Automation (ISA)/ IEC 62443-2-3 standard. It outlines ways to logically design an
OT patch management program for updates and logging. It’s also a good idea to include input from your system OEM provider because they test patches prior to release and can also provide guidance on which patches should be installed.
MATT MALONE
ICS/OT cybersecurity consultant / Yokogawa
Continuous vulnerability management
Vulnerability management is a large and important topic in both the IT and OT environments. IT has been addressing this issue for multiple decades, while it is a much newer issue in the OT space due to the increase in attacks that now directly target OT systems. In fact, in the past, the automation world actively discouraged patching or updating unless absolutely necessary; this now must change to address the incredible growth of cybersecurity threats to OT assets.
From our perspective, we do see many customers struggling to stay current. However, there are also several standards, guidelines and frameworks that can help. The key takeaways are that this is a manageable effort that will take time and resources to create or change processes and train personnel to accomplish. Perhaps the most important takeaway is that OT cybersecurity in general and vulnerability management specifically must be planned as a continuous effort with no anticipated end—much like we have come to view the quest for a safe plant environment.
On the general cobot/machine integration topic there are multiple industry-wide efforts to ease the integration of all types of machines or sub-systems into a manufacturing control system. One effort gaining traction with many control system OEMs is the module type package (MTP), based on the VDI/VDE/NAMUR 2658 standard, which aims to simplify integrating any sub-system to a distributed control system (DCS). Then specifically for cobots, there is a NIST publication—NIST Advanced Manufacturing Series 100-41—Best Practices for the Integration of Collaborative Robots into Workcells Within Small and Medium-Sized Manufacturing Operations. Additionally, most, if not all, of the cobot OEMs offer guides on how to best integrate cobots into manufacturing operations.
Now back to the vulnerability management issue. NIST and ISA/IEC created separate OT cybersecurity standards, which have effectively coalesced into a single body of knowledge over the last 20+ years. The ISA99 standards committee initially created the basis of what became the ISA/IEC 62443 international series of standards, which ad-
dress what cybersecurity technologies can be employed, how to employ them, how to manage installed systems, how service providers should prepare themselves and how OEMs should securely manage their product lifecycles and certify individual products.
The NIST 800-82r3—Guide to Operational Technology (OT) Security is used more for government related projects in the U.S. like defense industrial base and regulated utilities. However, the NIST Cybersecurity Framework (CSF) V2.0 is used extensively for evaluating current state and planning next steps in a cybersecurity program with a risk-based approach.
All the cybersecurity standards consider cybersecurity “hygiene” to be one of the core aspects of cybersecurity. This means following basic guidelines like individual logins with complex passwords that are regularly rotated and keeping the firmware and software current. So how do we do this?
There are three tiers of vulnerability management that could be described as manual, semi-automated and automated. Manual processes include creating an OT asset inventory list and then subscribing to multiple vulnerability notification systems. Those systems could be governmentbased, like the National Vulnerability Database (NVD), or vendor-provided, which may give better and more detailed information but will require one subscription per vendor.
The semi-automated systems will take an inventory list and find all the vulnerabilities and may allow for some management of the remediation process. Finally, a fully automatic system strives to identify the vulnerabilities, download the fix (new firmware or software service pack), present the queued remediations for approval and then deploy the fix automatically. The fully automated systems are typically deployed in an IT environment and have not found much adoption in OT due to a need for quality control with most OT organizations requiring in-depth testing, production coordinated scheduling and management of change processes.
Standards also advocate for other types of cybersecurity controls to implement a defense-in-depth style of protection with overlapping layers. These layers of protection might include deep packet inspection (DPI) firewalls, segmentation of different production areas, separation of IT and OT networks or intrusion detection systems (IDS). It is critical for long-term success to approach cybersecurity with a continuous-improvement, programmatic methodology.
CHUCK TOMMEY
digital connectivity expert / Siemens Digital Industries
Joey Stubbs joey.stubbs@gmail.com
What is composite-enclosure noise?
A
NEW SET OF materials is on the scene for enclosures. Composite materials, such as fiberglass, acrylonitrile butadiene styrene (ABS) plastics and recycled materials are becoming more mainstream and offer unique advantages for electrical enclosures, including resistance to corrosion, lightweight characteristics and ease of customization. However, prospective customers should also be aware of specific considerations related to electromagnetic interference (EMI) shielding and grounding schemes, which play a critical role in the effective operation of these enclosures.
Fiberglass enclosures are known for their durability and resistance to environmental factors such as moisture, chemicals and ultraviolet (UV) radiation. These enclosures are ideal for outdoor applications and harsh industrial environments. Their non-conductive nature also makes them suitable for applications where electrical insulation is critical.
but can be enhanced through additives, such as carbon, or by integrating conductive liners.
Prospective customers should ensure that the enclosures comply with relevant EMI standards, such as IEEE 299 or MIL-STD-461. Requesting third-party testing data or certifications can provide assurance that the enclosure meets necessary performance criteria.
Grounding is another critical factor in the performance and safety of electrical enclosures. Proper grounding for cabinet structures like DIN rails (Deutsche Institut für Normung) and back panels are essential to prevent electrical hazards and ensure reliable operation.
Electromagnetic interference (EMI) can disrupt the operation of sensitive electronic equipment.
ABS is a lightweight thermoplastic that offers excellent impact resistance and electrical insulation properties. ABS enclosures are often used in less demanding environments where aesthetic appeal and weight are the main considerations. However, they may not provide the same level of durability against harsh chemicals as fiberglass.
With increasing focus on sustainability, many manufacturers are turning to recycled materials for their enclosures. These materials can provide a balance of durability and environmental responsibility, appealing to companies looking to minimize their carbon footprint. However, the performance characteristics of recycled materials can vary widely, so it’s crucial to verify their suitability for specific applications.
Electromagnetic interference (EMI) can disrupt the operation of sensitive electronic equipment housed within industrial enclosures. EMI shielding is essential for maintaining signal integrity, especially in environments with heavy machinery or radio frequency (RF) sources.
When selecting a composite enclosure, consider the material’s inherent properties for EMI shielding. Fiberglass, while durable, often requires additional conductive coatings or meshes to provide effective shielding. On the other hand, ABS plastics typically have lower EMI shielding capabilities
DIN rails and back panels are commonly used for mounting electrical components such as circuit breakers, relays and controllers. It is essential to establish a reliable grounding connection to these components to prevent electrical faults. In composite enclosures, grounding can be achieved using metal grounding studs or bus bars attached to the DIN rail and internal panels. Ensure that these grounding points are accessible and that the grounding path is low-resistance to facilitate effective fault current dissipation.
Star grounding is a technique that connects all components to a single grounding point, reducing ground loops and interference. Single-point grounding, similar to star grounding, is an approach that ensures that components share a common ground connection, managing EMI.
Bonding ensures that all metal components within the enclosure are bonded together to create a continuous conductive path. This helps reduce the risk of electric shock and equipment failure.
Understanding the implications of EMI shielding and grounding schemes is vital.
Joey Stubbs is a former Navy nuclear technician, holds a BSEE from the University of South Carolina, was a development engineer in the fiber optics industry and is the former head of the EtherCAT Technology group in North America.
