Page 1

April 2008

MICA(P) 327/10/2007 | ISSN 0219/5615 | PPS 1561/7/2008 (000553)

Industrial

Wireless Infrastructure Effective Pump Monitoring Network

Security Making

Use o f

Waste

www.iaasiaonline.com


HOW CAN YOU MAXIMIZE YOUR OPERATIONS MANAGING FACILITIES AND BUILDING AUTOMATION, PROCESS CONTROL AND MANUFACTURING EXECUTION FROM R&D THROUGH COMMERCIAL PRODUCTION? ASK ROCKWELL AUTOMATION.

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• BOOTH D06 AT BIOMEDICAL BIOMEDICALASIA ASIA2008 2008 • APRIL 15 -16, 2008 • APRIL 15 -16, 2008 SUNTEC CITY •• SUNTEC CITY CONVENTION CENTER CONVENTION CENTER SINGAPORE SINGAPORE

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Tel: 662 936 1500

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Tel: 84 8 520 2786

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Copyright © 2006 Rockwell Automation, Inc. All Rights Reserved.

ENQUIRY NO. 776

VISIT USus at Visit AT BOOTH D06

Rockwell Automation Southeast Asia Pte Ltd


All You Need For Safety Field Bus Network

CC-Link Safety... meets the need of production sites for saving wiring costs while at the same time ensuring safety. This safety field network inherits high-speed communication from CC-Link and makes it possible to both meet safety requirements for production lines and provides the benefit of wire-reduction.

ENQUIRY NO. 648

Asean CC-Link Promotion Centre 307 Alexandra Road #05-01/02 Mitsubishi Electric Building Singapore 159943 Tel: (65) 6473 2308 • Fax: (65) 6476 7439 • Did: (65) 6470 2480 • E-mail: cclink@asia.meap.com • http://www.cc-link.org


contents APRIL 2008

28

24 Issues & Insights

24

Wireless Technologies: All In The Mix

Mix multiple wireless technologies in order to create the optimal commercial wireless solution. By Joel Young, senior VP & CTO, Digi International Inc

28

Cord Cutting Measures

The key to building an industrial wireless infrastructure is coordination and support. By Anthony F Porrazza, product manager, wireless, Honeywell Process Solutions

wireless technologies

All In The Mix

Control Point

32

34

CORD CUTTING MEASURES

Multiplying Your Performance

Software & Networks

36

Wireless Networks: Priority Security

An advanced and high-speed motion control system enables OEMs and system integrators to enhance their end products. By Philip Tang, sales engineer, Mitsubishi Electric

Wireless networks introduce significant security concerns as enterprises must address requirements for data safeguarding. By Peter Rysavy, president, Rysavy Research

Amplifying Efficiency

40

Physics Of Structural Automation

An adjustable frequency AC drive allows the user to effectively control motor output speed. By Schneider Electric South East Asia HQ

The interlacing of open standards results in the entire building being networked. By Citect Global Communications

36

WIRELESS NETWORKS: PRIORITY SECURITY

34 2  industrial automation asia | April 2008

AMPLIFYING EFFICIENCY


FLEXIBLE AIR FREIGHT SOLUTIONS FOR YOUR EVERY NEED

Talk with the DHL experts on 65-654 89567 or visit us at www.dhl-gf.com Air First, Air Premium and Air Value from DHL Global Forwarding provide air freight solutions for your time-sensitive, most precious and time-tolerant cargo. Through these services we consistently meet the ever-changing needs of businesses large and small from sectors including automotive, consumer products, engineering & manufacturing, life sciences & healthcare and technology. As you’d expect from the market leader, our extensive range of air and ocean freight services let you balance both speed and cost, enhancing your commercial advantage each and every day. Add to this a host of value added benefits and you can rest assured that we’ll always deliver a solution locally and globally.

Moving your business forward. Globally.


contents APRIL 2008

Instrumentation & Measurement

42

Effective Pump Monitoring Integrating continuous online pump monitoring with the plant’s control system to increase asset availability. By Jonas Berg, senior PlantWeb consultant, Emerson Process Management

Sector Spotlight

46

The Product Of Process

Organising the entire process chain to minimise unproductive downtimes and idle periods. By Klaus Langanke, sales representative, Siemens AG

In Business

50

52

Industrial Automation Asia (IAA) is published 8 issues per year by Eastern Trade Media Pte Ltd 1100 Lower Delta Road #04-02 EPL Building Singapore 169206. Tel: (65) 6379 2888 • Fax: (65) 6379 2805 Website: www.iaasiaonline.com Email: iaa@epl.com.sg

Partnering For Success

42

Effective pump monitoring

54

The launch of Centum VP adds to Yokogawa’s intent of climbing to the top of the industrial automation arena by expanding not only in South-east Asia, but in Europe and the US as well. By Eileen Chan

Moving Towards Complete Automation

Copyright. Eastern Trade Media Pte Ltd. All rights reserved. No portion of this publication covered by the copyright herein may be reproduced in any form or means – graphic, electronic, mechanical, photocopying, recording, taping, etc – without the written consent of the publisher. Opinions expressed by contributors and advertisers are not necessarily those of the publisher and editor.

Seven Common Pitfalls Of Outsourcing

57

Market Report: Robust Growth For Process Industry Automation

The market for process automation systems is expected to grow by 9.6 percent over the next five years. By Himanshu Shah, senior analyst, Arc Advisory Group

Design Focus

58

Partnering for success

Dr Tony Lee, Yokogawa

For more subscription information Fax: (65) 6379 2806 • Email: agnislim@epl.com.sg

IMPORTANT NOTICE The circulation of this magazine is audited by bpa world wide. The advertisers’ association recommend that advertisers should place their advertisements only in audited publications

Despite the significant benefits that come with outsourcing, there are also risks and challenges for OEMs to consider. By Arena Solutions & Symphony Consulting

Yokogawa’s latest DCS, the Centum VP, aims for ‘operational excellence’ . By Derek Rodriguez

50

Subscription Rates: IAA is available to readers on subscription in Singapore at S$60.00 per annum. Subscription by airmail to readers in Malaysia is also at S$60.00 per annum; and Asia Pacific, America, Europe and other regions at S$100. Refer to the subscription card in each issue for further details.

Making Use Of Waste

Waste-to-resources is an approach that involves the control of environmental pollution, waste minimisation and the consideration of waste products as potential resources before disposal. By Augustine Quek

Events

66

Autodesk World Press Day 2008

Design technology is vital to helping Asian companies innovate faster and more efficiently. By Derek Rodriguez

Refer to p68a for Advertisers’ Enquiry Numbers

Regulars 8 News 16 Profibus Association S E Asia 18 CAN in Automation 20 Fieldbus Foundation 22 EtherCAT Technology Group 62 Products & Services 67 Calendar of Events 68 Advertising Index / Ad Sales Office 68A Product Enquiry Card

Next Issue

Look out for topics on…  M2M  Warehouse Management & Control Systems  Gas Analysers/ Pressure Transmitters  Power Generation  Entrepreneurial Impetus

Cover: Emerson Process Management

4  industrial automation asia | April 2008


Greener buildings that don’t cost the earth

Keen to become a Citect Integration Partner? Email your company details to Citect today!

Citect Southeast Asia HQ

Tel: +65 6482 2212

Fax: +65 6482 2252

For more information visit www.citect.com

Email: sales.asia@citect.com

ENQUIRY NO. 768

Citect’s facilities management solution reduces energy usage and operating costs, and improves tenant services. CitectFacilities integrates building automation systems such as climate, lighting and access control, CCTV and fire, into a single consistent solution and provides specialised power monitoring and energy management for single or multiple-site facilities. By offering unrivalled reliability, flexibility and openness, CitectFacilities gives Property Owners and Facility Managers the peace of mind that their investment will be protected long into the future.


editor’s page

Going On

Soft

Published by:

EASTERN TRADE MEDIA PTE LTD

Hard Wires

Many inventions and advancements have claimed to be ‘the best thing since sliced bread’. None have truly attained the mantle. Wireless technology has certainly been gaining ground in recent years, rapidly increasing its influence commercially as well as in the industrial setting. On World, a wireless research company, predicted late last year that user growth rates for wireless applications in industrial companies will continue rising and by 2011, industrial wireless sensor networking systems and services will be worth US$4.6 billion. The technology is not without its downside, however. Issues with security have yet to be completely resolved. Despite measures to protect data, it will still avail itself to tampering or even theft. In 2003, Californian politician Debra Bowen, in reference to RFID, asked: “How would you like it if one day you realised your underwear was reporting on your whereabouts?” Though her light-hear ted question sugar-coated the point she was making on privacy, she was certainly not exaggerating the potential of RFID, one of the in-vogue consequences of wireless technology. Already in Singapore, the technology has invaded the lives of the people. The EZ-Link smart card, originally designed as a farecard, has begun to be implemented as an attendance-marking tool in schools. ERP gantries placed around the island mercilessly subtract value from the cashcards of motorists who drive under them. Man’s relentless quest for power means that a ‘Minority Report’ civilisation is not just a reel concept. RFID implants are not unheard of and will surely develop a larger voice in due time. Back in reality, this month will see the event of RFID World Asia in Singapore. We too, will be setting up a booth there. Do drop by and visit us if time affords you to. Hope to see you there!

Wireless technology has certainly been gaining ground in recent years, rapidly increasing its influence commercially as well as in the industrial setting

(A fully owned subsidiary of Eastern Holdings Ltd) Managing Director

Kenneth Tan

Managing Editor

Eileen Chan eileenchan@epl.com.sg assistant editor

Derek Rodriguez derekrodriguez@epl.com.sg Senior Editorial Assistant/ Marketing Support

Norjana Taib norjanataib@epl.com.sg

Senior Art Director/Studio Manager

Lawrence Lee lawrencelee@epl.com.sg Graphic Designer

Katherine Ching katherineching@epl.com.sg Sales & marketing Manager

Caroline Yee carolyee@epl.com.sg

Circulation MANAGER

Caroline Rayney carolinerayney@epl.com.sg Circulation Executive

Agnis Lim agnislim@epl.com.sg Contributors

Joel Young, Anthony F Porrazza, Philip Tang, Peter Rysavy, Jonas Berg, Klaus Langanke, Himanshu Shah, Augustine Quek, Schneider Electric, Citect, Arena Solutions, Symphony Consulting Editorial Consultants

Jim Pinto

Industry Analyst

Alastair Ross Director, Codexx Associates Ltd

supported by:

EASTERN HOLDINGS LTD executive Board Chairman

Stephen Tay GROUP EXECUTIVE DIRECTOR

Kenneth Tan

Financial Controller

Boris Chan

etm

Eastern

Trade Media Pte Ltd an Eastern Holdings Ltd company

Head Office & Mailing Address: Eastern Trade Media Pte Ltd 1100 Lower Delta Road #04-02 EPL Building Singapore 169206 Tel: (65) 6379 2888 • Fax: (65) 6379 2805 Website: www.iaasiaonline.com Email: iaa@epl.com.sg MICA (P) No. 327/10/2007 ISSN 0219/5615 PPS 1561/7/2008 (000553) Co Reg No. 199908196C Colour Separation: Pica Digital Pte Ltd Printer: Fabulous Printers Pte Ltd

Derek Rodriguez Assistant Editor

6  industrial automation asia | April 2008


ENQUIRY NO. 756


Industry News

First Reverse Osmosis Desalination Plant Singapore: PowerSeraya has spent approximately S$20 million (US$14.1 million) to build a 10,000 m³/day Seawater Reverse Osmosis (SWRO) desalination plant at Pulau Seraya Power Station on Jurong Island. The plant uses 16 inch (400 mm) diameter membrane SWRO technology. The prior industry standard was an 8-inch (200 mm) diameter. The new addition of water production to its integrated energy

portfolio will create further efficiencies through creating a Combined Heat, Water and Power (CHWP) platform for the company. PowerSeraya’s MD Neil McGregor said: “In a resource-constrained world, the move to produce desalinated water as part of our process, is not only good for the environment, but it makes good business sense as well. We have to find approaches of getting more for less in a sustainable way through innovation.”

By harnessing its natural advantage of being near to deep and low salinity water and integrating its heat, water and power processes, PowerSeraya has been able to create an intelligent, virtuous cycle of electricity, steam and water generation. “The plant sets new standards by lowering the energy consumption from over 4 kWh per cubic metre to 2.85 kWh per cubic metre. This translates to an equivalent of 30 percent reduction in electricity consumption and more significantly, cost,” explains Mr McGregor. The plant also uses an energy management system to ramp up water production during low electricity price periods. At the heart of this operation are high efficiency variable speed drive (VSD) pumps with the ability to match variable electricity pricing during peak and off peak periods. “If a water market was to evolve on Jurong Island or in Singapore, we would be interested in expanding our capability. Similarly, we can leverage on this additional capability and replicate the CHWP footprint to expand overseas,” said Mr McGregor. ENQUIRY NO. 2101

DHL Addresses Climate Change Singapore: DHL has a carbon neutral shipping service called DHL Gogreen Express in Asia Pacific. The service will be available in 17 countries across the region over the course of this year. Through customer payment of an additional three percent ‘green premium’ on top of standard delivery charges, DHL calculates the carbon emissions generated by transporting each specific customer shipment from the country of origin to destination, and offsets these emissions by reinvesting in certified carbon management programs such as alternative fuel vehicle technology, solar panels and reforestation projects. Customers can choose to send all or a selection of their international shipments as part of this service. In addition, customers will each receive an annual certificate from DHL stating the total amount of carbon dioxide, which was offset on their behalf during the year. ENQUIRY NO. 2102

8  industrial automation asia | April 2008


Industry News

Lanxess To Build Butyl Rubber Plant In Singapore Singapore: Specialty chemicals group Lanxess is to build a butyl rubber production plant in Singapore with an annual capacity of up to 100,000 metric tonnes. It is due to be commissioned in 2011. The plant will be constructed in the Tembusu Cluster of Jurong Island. The investment project is worth some E400 million (US$615 million). Following completion of the construction project, Lanxess is looking to employ over 200 staff at the new site. Singapore was chosen following a detailed analysis of a wide range of location factors. “Probably the overriding argument in Singapore’s favour is the excellent availability of raw materials for butyl rubber production,” explained Ron Commander, head of the business unit.

Lanxess has secured supplies of the key raw material through a long-term contract with Shell Eastern Petroleum before construction has even started. The company also aims to conclude long-term supply agreements with Asian producers for isoprene. Also, Lanxess has significantly expanded its two existing production sites in Zwijndrecht, Belgium and Sarnia, Canada in the last two years. Once the latest expansion phase in

A New Approach to Monitor Bearing Wear and Shaft Imbalance

Sarnia is completed, the company will have an annual capacity totaling 280,000 metric tonnes of butyl rubber from 2009 onwards. Sustainable annual market growth for butyl rubber of around three percent is expected in the next 15 years. Major growth areas are China, Taiwan and Hong Kong at around six percent per annum, and India, at more than eight percent. ENQUIRY NO. 2103

ifm electronic

Vibration Monitor Innovative technology Octavis is a self-contained vibration monitor with the technology to determine vibration signatures, interpret fault data and signal an alarm condition. This new hardware platform offers tremendous advantages over traditional monitoring systems that require accelerometers, data collectors and expensive software. Continuous monitoring solution Octavis is designed to be permanently mounted on a pump, spindle, compressor, or a fan to monitor failure conditions of bearings or shafts. Continuous monitoring eliminates the need for taking time-based reading and is much more reliable and costeffective then intermittent solutions.

Operating Condition OK

Early warning or bearing worn or shaft unbalance

email: sales.sg@ifm.com • website: www.ifm.com

Critical indicates bearing damage orextreme shaft unbalance

ENQUIRY NO. 766

Integrated expertise Octavis incorporates a DSP chip with enough processing power to analyze a vibration spectrum and predict failures in advance by sending an alarm output signal to a PLC or relay. A highly visible “traffic light” bar graph display indicates the operating condition of the bearing or shaft.

April 2008 | industrial automation asia  9


Industry News

TCM RFID System To Be Used In Hospitals Singapore: The National Healthcare Group (NHG) of hospitals in Singapore has awarded a contract to local real-time systems solutions provider, TCM RFID to help staff keep track of pharmaceuticals and ensure proper administration of drugs to patients. The Intelligent Medicine Dispensing System (i-MDS), the first of its kind in Asia, will be operational by the second quarter of 2008. The system runs on customised software developed by TCM RFID, and will be deployed initially on more than 300 Motorola MC50 and MC70 enterprise digital assistants (EDA) at two NHG hospitals. Said MD Michael Oh: “The system is set up to ensure that all the right procedures are being followed when it comes to the administering of drugs to patients.” Mr Oh also said the system would also help to improve hospital workflow management by cutting down the need to look for paper files, and hence free up time for staff to provide better quality care to patients. ENQUIRY NO. 2104

Regional Network Hitachi Asia Ltd Hitachi Asia (Thailand) Co. Ltd Hitachi Asia (Malaysia) Sdn. Bhd Hitachi Asia Ltd – Philippines Branch

China Achieves Total Export Of US$153 Billion China: According to the National Bureau Of Statistics Of China, the value-added of industrial enterprises with an annual sales income of over 5 million yuan (US$0.7 million), increased 15.4 percent from January to February. Industrial enterprises achieved a total export delivery value of 1082.8 billion yuan (US$153 billion), a rise of 14.8 percent. The report stated that the growth rate of manufacture of textile, raw chemical materials and chemical products, non-metallic mineral products, smelting and pressing of ferrous metals expanded by respectively 11.6, 13.3, 19.7 and 14.0 percent; that of manufacture of general purpose machinery, transportation equipment manufacturing industry, electromechanical equipment manufacturing climbed 21.9, 18.8 and 20.3 percent; that of manufacture of communication equipment, computers and other electric equipment increased 14.5 percent; and that of production and supply of electric power and heat power rose by 11.8 percent. ENQUIRY NO. 2105

As a regional headquarter, Hitachi Asia Ltd (HAS) markets electric motor, air compressor and digitalized inverter. It is also responsible for the marketing of various industrial products such as programmable logic controller, ink jet printer, hoist, vortex blower, contactor and circuit breaker.

Hitachi Variable Frequency Drives SJ-Series

Hitachi Asia Ltd • Hanoi / Ho Chi Minh City Hitachi Asia Ltd – Jakarta Office Hitachi India Trading Pvt. Ltd • New Delhi / Bangalore / Mumbai

Regional Distributors / Dealers

New

• Thailand

SJ700 Series

High Performance Inverter with High Starting Torque and Built-in Programming Function

SJ300 Series Full-feature Performance for Applications Requiring High Starting Torque and Functional Versatility

• Singapore • Malaysia

NEW

SJ200 Series Compact Inverter with High Starting Torque and User-friendliness

• Indonesia

L-Series & X-Series

• Philippines • Vietnam

L300P Series

• India

Enhanced Energy-Saving Function for General Applications

• Pakistan

L200 Series

• Sri Lanka

Compact Standard Inverter for Energy-Saving Applications

• Bangladesh

ENQUIRY NO. 737

• Middle East Countries (Egypt, Saudi Arabia, Dubai, Oman, Bahrain, Qatar, Kuwait, Syria etc)

X200 Series NEW

Hitachi Asia Ltd 24 Jurong Port Road, #03-05 Office Block, CWT Distripark Singapore 619097 Tel: +65 6305 7400 • Fax: +65 6305 7401 • URL: www.hitachi.com/asia • Email: ice@has.hitachi.com.sg

10  industrial automation asia | April 2008

New

New Generation Compact Inverter with Trip-less and User-friendly Features


Industry News

Philips Increases Sales Of Green Products By A Third

ENQUIRY NO. 2106

Online Corrosion Monitoring Partnership Mannheim, Germany: Pepperl+Fuchs GmbH and TÜV Süd Chemie Service GmbH have agreed on a cooperative partnership arrangement for the implementation of projects involving the operational online monitoring of corrosion rates in the chemical industry. TÜV Süd Chemie Service is a service provider in the area of the operational online use of corrosion detection equipment, including the preparation, selection and adaptation of the system to the respective operational requirements by means of laboratory investigation. Pepperl+Fuchs supplies measuring devices for corrosion monitoring. ENQUIRY NO. 2107

www.turck.com

Want to knoW What‘s coming? modular rF identiFication systems New advantages for industrial requirements with RFID from TURCK. • More efficient production based on higher application speeds: Typical read/write time 0.5 ms per byte • Flexible integration based on modular design: 2, 4, 6 or 8-channel interfaces, various shapes of read/ write heads • Unlimited application due to expanded temperature range: Data carriers for high temperatures up to 210 °C • High system availability based on state-of-the-art storage technology: Long-life FRAM data carriers, for virtually unlimited number of write operations • Simple integration into control environment: Interfaces for PROFIBUS-DP, DeviceNet™, Ethernet Modbus-TCP, PROFINET IO, EtherNet/IP BL ident® from TURCK – Reliable data transmission in temperature ranges up to 210°C.

TURCK Singapore Pte. Ltd. 25 International Business Park #03-22/23 German Centre, Singapore 609916 Phone +65 6562 8716, Fax +65 6562 8719 E-Mail singapore@turck.com

ENQUIRY NO. 761

Singapore: Royal Philips Electronics has achieved a 33 percent increase in sales of green products in 2007 resulting in total sales of E5.3 billion (US$8.15 billion) in 2007, compared with E4 billion (US$6.15 billion) in 2006. Philips continued its steady advance in energy efficient lighting solutions with an increase in green lighting sales of 17 percent. The biggest increase was in the home lighting market followed closely by lighting solutions for retail outlets and street lighting as well as LED lighting. Sales of green healthcare products increased by 35 percent. The consumer lifestyle sector showed a very significant increase of 91 percent in sales of green products. In Singapore, Philips Innovation Campus, its largest product development centre outside the Netherlands, plays a key role in contributing to Philips’ Green Product portfolio. The Innovation Campus contributed to 50 percent of the total green products introduced to date in the global markets this year. The centre is developing 28 green products to be launched in 2008.

April 2008 | industrial automation asia  11 S0208_RFID_80 x 240_EN.indd 1

27.02.2008 09:38:22


Industry News

ABB And Tetra Pak Join Forces Wonderware Obtains Lund, Sweden: ABB and SCP Certification Tetra Pak have established a joint engineering network to share expertise and resources in order to speed up implementation of Tetra P a k ’s i n d u s t r y l e a d i n g Tetra PlantMaster plant automation solutions. During 2008, services will be offered to other European markets like Netherlands and Spain, and also to other global customers who use ABB technology. “Together with ABB, we will be able to speed up deliveries of leading edge automation solutions based on Tetra PlantMaster,” said MD Marie Samuelsson. “Automation controlled by Tetra PlantMaster will bring customers flexible functionality, future scalability and customisation to their specific product range,” she said.

California, USA: Wonderware, a business unit of Invensys, has achieved the Service Capability and Performance (SCP) certification. The Wonderware Technical Support Centre team successfully completed the certification process, involving independent, rigorous measures of best practices in the services industry, which represents a benchmark for support organisations around the globe. To achieve SCP certification, a company must exceed stringent requirements in customer support services. Companies are judged in several categories including customer feedback, services delivery, training, total quality management, sales and services, research and development, and corporate commitment and strategy. “The SCP audit and certification process confirms Wonderware’s dedication to operational excellence and its commitment to achieving the highest possible levels in customer satisfaction,” said Neal Hatton, Wonderware director of technical support.

ENQUIRY NO. 2108

ENQUIRY NO. 2109

To realize safety, comfort and fulfillment in people’s lives and contribute to the global environment through "human-centered automation" Brand new HPX-AG series • Easy operation / tuning • Gang-mounting • Long sensing distance up to 2230mm • Repeatability of up to +/-5µm • Smallest detectable object of 5µm dia • Environment-friendly design • Variety of fiber cables

Digital Controller SDC15 series

ENQUIRY NO. 767

• Compact body with depth of only 60mm • Front panel thickness of only 2mm • Improved controllability • Auto/Manual changeover • Heat/Cool functions • 3 Event relay outputs • Internal event configuration function • PC loader connection available

12  industrial automation asia | April 2008

Yamatake Controls Singapore Pte Ltd

Blk 26 Ayer Rajah Industrial Estate, #01-06/07/08, Ayer Rajah Crescent, Singapore 139944. Tel: (65) 6778 5966 • Fax: (65) 6778 0012 • Website: www.yamatake.com.sg • Email: ysp@yamatake.com.sg


Industry News

Testing Programme Reaches Milestone California, USA: Since the LonMark professional certification testing programme was launched at the AHR show in Dallas in January 2007, close to 135 individuals have taken the test. The test is open to any industry professional involved in the design, specification, integration or installation of Lon control networks. Those passing the test are recognised LonMark certified professionals and hold the credentials associated with comprehensive Lon technology knowledge. The 150 multiple-choice questions cover 12 subject areas, including LonWorks history and terminology, physical and logical network structuring, installation, communication, LonWorks and IP, and user interfaces.

Service For Industrial Equipment Manufacturers Illinois, USA: Industrial equipment manufacturers and their suppliers can obtain gratis assessments by InterTech’s testing applications laboratory on whether helium leak test methods can be replaced by customised mass flow leak test methods without sacrificing accuracy. This service is especially geared to help identify applications with leak test requirements in the 0.01 sccm range and for leak testing heat exchangers such as radiators that can be successfully handled by expert techniques applying mass flow leak test methods. Jacques Hoffmann, president comments: “Some have reported helium price rises as high as 30 percent last year. InterTech provides both designing mass flow leak tests or helium leak testing. The first step is in identifying the best test method to meet application requirements.”

ENQUIRY NO. 2110

ENQUIRY NO. 2111

Mail for you

ADVANTECH MONITORINGSYSTEM SYSTEM ADVANTECHENVIRONMENT ENVIRONMENT MONITORING Application story for Advantech ADAM-4000 Series Application story for Advantech ADAM-4000 Series

Mail for you

Environmental Monitoring

Environmental Forum inMonitoring May 2008 Forum in May 2008 Find out more @

Find out more @ http://www.eautomationpro.com/sg/ http://www.eautomationpro.com/sg/

Shipyard Fire Monitoring System Shipyard Fire Monitoring System

Korean system integrator applied Advantech’s ADAM-4000 AA Korean system integrator applied Advantech’s ADAM-4000 SeriesSeries existing telephone lines in order to up setaup fire alarm toto existing telephone lines in order to set fireaalarm for for Samsung Heavy Industries (SHI), Korea. Samsung Heavy Industries (SHI), Korea. SHI enjoys a good reputation among customers worldwide SHI enjoys a good reputation among customers worldwide for for delivering toptop quality products on time. TheyThey manufacture superdelivering quality products on time. manufacture superlarge container ships, crude oil tankers, bulkbulk carriers, as well large container ships, crude oil tankers, carriers, as as well as high-value added vessels. The area of this shipyard is approximately high-value added vessels. The area of this shipyard is approximately 3,292,576 square metres. 3,292,576 square metres.

ADAM-6000 Series

RS-485 Serial Interface Serial Interface ■ ■■RS-485 Supports Modbus/RTU and ASCII Supports Modbus/RTU and ASCII Protocol ■ Protocol Comprehensive I/O Modules ■Comprehensive Modules accept I/O direct Thermocouple ■ (even(even and RTD Inputs) accept direct Thermocouple

■ ■

■■■ ■■ ■

andAnalog RTD Inputs) Input Module capable of performing Analog Input Module capable of Digital Output Independently performing Digital OPCOutput Server Independently Available OPC Server Available

delays in the ship-building schedule.

ADAM-6000 Series

ADAM-4000 Series

Both ADAM-4000 & 6000 series

the same I/O Modules Both are ADAM-4000 & 6000 series are the same I/O Modules

© 2008 Advantech Co. Singapore Pte Ltd

© 2008 Advantech Co. Singapore Pte Ltd

■ ■■ ■

10/100Mbps Ethernet Interface 10/100Mbps Ethernet Interface Supports Modbus/TCP Protocol Supports Modbus/TCP Protocol Supports UDP Protocol for Real-time Supports UDP Protocol for Real-time Application by Event Triggering /Data Application by Event Triggering /Data Streaming Functions Streaming Functions Complete I/O in a Single Module Complete I/OServer in a Single Module Built-in HTTP Built-in HTTPOPC Server Modbus/TCP Server Avaliable

Modbus/TCP OPC Server Avaliable

www.advantech.com

www.advantech.com

Advantech ADAM-4000 Series have been installed in 5 different plant Advantech ADAM-4000 Series from havefield beenfire installed 5 different plant locations to collect digital signals sensorsin (refer to locations toshown). collect digital signals from field fire sensors (refer illustration The application software is developed in a to illustration shown). The application software is developed in a Visual Basic environment.

Visual Basic environment.

SHI has chosen Advantech’s ADAM-4000 Series due to the flexibility, SHIof has chosen Advantech’s ADAM-4000 Serieswith due the to the ease use and cost-effectiveness. SHI is satisfied newflexibility, fire ease of use and cost-effectiveness. SHIsame is satisfied with monitoring system and plans to set up the shipyard firethe new fire monitoring system plans to set up the same shipyard fire monitoring system in 3and other locations.

monitoring system in 3 other locations.

Authorised Microsoft Windows Embedded Distributor Authorised Microsoft

Windows Embedded Distributor

Singapore (South Asia Pacific Headquarter) Tel: 65-6442 1000 Email: sg@advantech.com Thailand, Bangkok Tel: 66-2-248 3140 Email: sales@advantech.co.th Singapore (South Asia Pacific Headquarter) Tel: 65-6442 1000 Email: sg@advantech.com Australia: Melbourne Tel: 61-3-9797 0100 Email: info@advantech.net.au, Sydney Tel: 61-2-9482 2999 Email: info@advantech.net.au Thailand, Bangkok Tel: 66-2-248 3140 Email: sales@advantech.co.th Malaysia: Kuala Lumpur Tel: 60-3-8075 6196 Email: sales@advantech.com.my, Penang Tel: 60-4-397 3788 Email: sales@advantech.com.my

Australia: Melbourne Tel: 61-3-9797 0100 Email: info@advantech.net.au, Sydney Tel: 61-2-9482 2999 Email: info@advantech.net.au Malaysia: Kuala Lumpur Tel: 60-3-8075 6196 Email: sales@advantech.com.my, Penang Tel: 60-4-397 3788 Email: sales@advantech.com.my

ENQUIRY NO. 760

ADAM-4000 Series

Due toto thethe vast space of the plant andand out out of safety concern for the Due vast space of the plant of safety concern for the workers, SHISHI initiated a fire alarm project to monitor the fire workers, initiated a fire alarm project to monitor thealarm fire alarm status of the whole plant on a real-time basis; to detect and respond status of the whole plant on a real-time basis; to detect and respond toto anomalies (fire signals) andand releases fire alerts in order to avoid anomalies (fire signals) releases fire alerts in order to avoid delays in the ship-building schedule.

April 2008 | industrial automation asia  13


Industry News

Exxon Mobil To Invest At Record Levels New York, USA: Exxon Mobil Corp chairman and CEO Rex Tillerson has announced plans to invest more than US$125 billion in capital spending over the next five years to deliver major projects to help meet growing world energy demand. “We will invest record amounts to develop new technology, bring on new upstream projects, increase our base refining capacity and grow our chemical business,” Mr Tillerson said. From 2008 to 2010 alone, Mr Tillerson said, the company expects to participate in the start up of 19 new projects which, at peak, would collectively add more than 725,000 oil-equivalent barrels per day to production. The company expects to start up multiple projects over the next three years across the full value chain of the liquefied natural gas (LNG) business, including production, transportation and distribution. Using its proprietary technology, the company will commission four of the world’s largest liquefaction facilities and new LNG ships which can carry 80 percent more natural gas than conventional ships. ENQUIRY NO. 2112

The PAC Turns Five

Virginia, USA: The first programmable automation controller, PACSystems was unveiled five years ago by GE Fanuc Intelligent Platforms. “Back then, PACSystems was considered revolutionary,” said Bill Estep, VP of the company’s control systems business. “With one engine, coupled with a single development tool, users could take advantage of a powerful engineering environment for multiple applications.” “Manufacturers and OEMs make their controller selections based on factors which lead to the lowest total cost of ownership such as adherence to open industry standards, multi-discipline control functionality, and ease of integration,” said Craig Resnick, research director, ARC Advisory Group. “Demand for PACs is projected to strengthen even further across all discrete, hybrid, and process industries,” Resnick continued, “as manufacturers and OEMs will increasingly specify and require PAC functionality for an ever growing number of applications.” SI-698-Triflex Prog 85x114

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ENQUIRY NO. 751

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Industry News

APPOINTMENTS & NOTICES Celona Technologies Appoints CEO Celona Technologies have appointed Charles Andrews as their new CEO to help aggressively build Celona’s customerfacing sales, support activities as well as to develop their industry leading application data migration software. Tony Sceales, Celona’s CTO said: “We plan to grow our product and service offering, introduce Celona Evolve to the global market and increase our market share within the UK.”

Avnet Azure Gets Award Singapore: Avnet Azure, an operating company of Avnet Technology Solutions, has received the IBM partner of the year award for the 7th consecutive year. Commenting on the awards, William Chu, VP and GM of the company said: “Avnet Azure has been an IBM distributor ever since we started back in 1996. Value-added support and a focus on channel partnership are very much a part of Avnet’s philosophy, and we are fully committed to delivering the value products, programmes and services that will make our vendors and partners successful.” ENQUIRY NO. 2115

N-TRON Introduces Six New - 40ºC to 85ºC Industrial Ethernet Products to its lineup

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Apex Names MD

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1005TX

The Technology Council of Southern California honoured George Klaus, executive chairman of the Board of Epicor Software Corp, with the 2008 Lifetime Achievement Award. Mr Klaus mentioned he was looking forward to seeing the continued growth of Southern California as a hotbed of technology leadership and innovation.

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ENQUIRY NO. 762

John Nichols, formerly director of business development, has been appointed MD of Apex Manufacturing Solutions. Mr Nichols is responsible for setting the company’s strategic direction and implementing best business practices and procedures. He also joins Apex’s ownership ranks as an equal equity owner and managing member of the limited liability company.

April 2008 | industrial automation asia  15


Industry Updates Vertical Integration With Profinet

‘Up’ & ‘Down’ The first important aspect is the integration of the established fieldbus world. This ‘downward’ integration comes in useful in system extensions, ie: when a fieldbusbased solution is already present in existing plant units. The second aspect is the integration of automation systems in Manufacturing Execution Systems (MES) and Enterprise Resource Planning (ERP). It is gaining increasing importance in company-wide, universal information systems. This ‘upward’ integration is the precondition for optimum deployment of production capacity. The development of automation to open, distributed systems with which machines or systems can be modularly constructed represents a further integration aspect.

Profinet Proxy

Proxy

ProfiBUS

INTERBUS

Integration of fieldbus systems

Implementation Profinet enables the integration of all existing fieldbus systems such as Profibus, AS Interface, DeviceNet and Interbus without having to alter any of the existing field devices. Besides process user data, Profinet can also supply MESrelated data, thus offering an ideal condition to support MES and ERP systems. It is necessary in many cases, especially with regard to system expansions, to integrate existing plant and machine parts without undertaking any modifications. The Profinet proxy concept specifies a model to integrate existing Profibus and other fieldbus systems such as Interbus and DeviceNet. Fieldbus solutions can 16  industrial automation asia | April 2008

Control Level

Field Level

Inventory

Maintenance

MES

Enterprise Resource Planning System

Quality

ERP

Production

By integrating information technology (IT) in the automation process, the possibility of markedly improved communication opportunities opens up. This can only be carried out cost-effectively in plants if an efficient solution for vertical as well as horizontal integration of the various communication participants is already in place. Such a solution uses Ethernet as the core of and starting point for communication.

Controller/DCS

• Factory Automation • Process Automation PROFINET devices support MES

Vertical integration with MES

be easily and seamlessly integrated in a Profinet system thanks to proxies. MES – Maintenance Operations To support the functional and vertical integration, the Maintenance Operations have been specified as a component of the interface to the MES level for Profinet in the initial phase. The so-called ‘Operations’ are located in the section ‘Maintenance’. They describe the actions in the MES as well as the necessary interactions between the MES and the ERP systems. Profinet uses an expanded traffic light system to represent the condition of the devices. This system allows for ‘Faulty device’ as well as the advance warnings of ‘Maintenance required’ and ‘Maintenance request’. A further MES-related function of Profinet is the ability to define the devices installed in the systems both clearly and electronically. Profinet CBA Profinet CBA can be used to create modular systems for distributed automation. The component model of Profinet CBA describes autonomously operating units of machines or plant as technological modules. A distributed automation system whose design is based on the technological module radically simplifies the modularisation of plant and machinery and in consequence their reusability. The engineering of distributed automation plant is divided between the programming of control logic of the individual technological modules (manufacturer of specific project planning tools) and the manufacturer-neutral project configuration of the entire plant, with which the communication relationships between the technological modules can be defined. ENQUIRY NO. 2116


ENQUIRY NO. 647


Newsdesk

Easy Link The CiA 402 device profile for electric drives simplifies the system integration of electric drives into CANopen networks. By Holger Zeltwanger, MD, CiA

M

any manufacturers have equipped their electric drives with a CANopen interface according to the device profile CiA 402. A CANopen device manages its communication and application parameters in the Object Dictionary. The Object Dictionary is the interface between communication software and application programme. This device offers standardised communication objects for the transmission of process data and configuration data. To synchronise actual and desired values, CANopen provides the sync message and synchronous process data objects. Together with further communication objects such as time stamp, the emergency object, and the error control message, it enables the flexible network configuration tailored to the application. It also defines a status machine for the network management (NMT state machine), which enables the defined start-up of a network. Further Standardisation To enable devices to communicate via ‘plug-and-play’ with very little system integration, an even higher degree of standardisation than OSI layer 7 application layer is needed. These device profiles define which communication and application objects in the Object Dictionary must be supported. They also define what data the process data consist of. On top of this, the profiles define how the devices operate by default. Despite all of this, the profiles still leave room for manufacturer-specific functionality. Device Profile The CiA 402 device profile for electric drives has been submitted for international standardisation and will be published as IEC CD 61800-7-1/2/3 later this year. It defines the functional behaviour of stepper motors, servo motors and frequency converters. To be able to describe the different types of drives, it specifies separate modes of operation and device parameters. Every mode of operation provides different objects such as maximum speed, acceleration, etc to achieve the desired actuation behaviour. The device profile supports the mode ‘Homing’ with which the drive finds a reference position. It supports several versions of homing. Homing runs with end switches can be described as homing runs that use index impulses. 18  industrial automation asia | April 2008

Start 0

10 12

Quick stop active

16 11

Not ready to switch on 1 Switch on disabled 2 7 Ready to switch on 3 6 Switched on

15

Fault

13

Fault reaction active

14

8

9

4 5 Operation enabled

Power-off or reset

CiA 402 finite state automaton (FSA) for electrical drives such as frequency converter, servo controller, and stepper motor.

Additionally the parameters required for the homing run (eg: speed, acceleration) can be configured. Target positions in the ‘Profile Position’ mode can be started in a defined way by configuring the speed and acceleration values in the operational profile. The operation mode ‘Interpolated Position’ allows the description of axes movements interpolated over time. This enables synchronising of several axes. The ‘Profile Velocity’ mode can be used to control the speed of a drive without having to specifically consider its position. ‘Profile Torque’ and ‘Velocity’ are used for controlling the torque and/or the speed of the drive. The velocity mode was introduced for frequency converters specifically; it provides boundary values and ramp functions. The device profile enables drive manufacturers to implement further, manufacturer-specific operation modes along with the defined ones. A drive that implements CiA 402 may support several modes of operation; it cannot, however, run several modes of operation all at the same time. The profile enables dynamically switching from one mode to the other. The state machine inside the profile describes the internal and external device behaviour. State transitions are initiated by sending the status word or by events inside the


device. Users may check the status of the drive by reading out the status word. Before a drive is ready for operation, several drive functions must be parameterised. For this purpose, the drive passes through the Power Disabled state. The transition from Ready-To-Switch-On to Switched-On correspond to turning on the power. Drive parameters may be changed in the state Ready-To-SwitchOn and Power Enabled. Axes movements only take place in the state Operation Enabled. The state Fault Reaction Active can be accessed from any of the other states if the device discovers an internal error. The device profile defines the process data object (PDO) composition besides the operation modes and the status machine. Every PDO that is sent by the drive provides the current state of the drive (status word). This ensures that the receiver gets the information whether the drive is working in the correct state. To make sure that commands are executed in the correct state, every single PDO contains this status word. Of course, the PDO also contains parameters. PDO Mapping The type-specific PDO mapping is going to simplify the configuration of a drive via the CANopen network in the future. It was added to the CiA 402 profile at the end. So far, the CANopen device profile defined seven transmit process data objects (TPDO) and eight receive PDOs (RPDO). This generic PDO mapping required

configuring the PDOs depending on the mode of operation since a CAN-identifier (ID) is mapped to only four TPDOs respectively RPDOs. The remaining PDOs had to be configured by the system integrator until now. To reduce this configuration effort, the profile now contains just one specific PDO mapping for frequency converters, and one for servos and steppers. The object 0x1000 in the Object Dictionary in bit 22 contains the information which PDO mapping has been implemented. All TPDOs are sent event-triggered (when a certain defined event takes place) and when the drive is started up. For frequency converters three TPDOs and three RPDOs were specified. They contain the status word, the current speed (TPOD 1, RPDO 1), and the current torque (TPDO 2, RPDO 2). The third TPDO and RPDO may be used manufacturerspecifically. TPDO and RPDO four to 16 are reserved. The specific PDO mapping for servos and steppers is identical. TPDO 1 transmits the status word, TPDO 2 the current position, TPDO 3 the current speed. The TPDOs are used periodically (100 ms). TPDO 4 and RPDO 4 may be used manufacturer-specifically. RPDO 1 contains the status word, RPDO 2 the required position, RPDO 3 the required speed. The type-specific PDOs are mainly used to drives with limited functionality. Products with special functions must be configured in most cases. SG-727-CFRobot 85x114

ENQUIRY Uhr NO. 2117 29.10.2007 14:21 Seite 1

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April 2008 | industrial automation asia  19


2008 General Assembly Reflects Global Fieldbus Growth

Regardless of whether attendees w e re e n d u s e r s i m p l e m e n t i n g a F o u n d a t i o n f i e l d b u s c o n t ro l architecture, EPCs looking for information about the technology, or suppliers seeking to expand their product market, the Fieldbus Foundation’s 2008 General Assembly was a ‘can’t miss’ event for the global automation industry. This year’s General Assembly was held in Antwerp, Belgium, on Feb 27-29, at the Antwerp Hilton Hotel. Open to Fieldbus Foundation members and non-members, the event included Foundation technology suppliers, end users, and industry participants from around the world. The 2008 General Assembly theme, ‘Why Foundation Has Become The Standard’, reflected the growth of Foundation fieldbus as the global ‘technology-of-choice’ for process automation. Foundation technology now holds a major share of European chemical, pharmaceutical, and oil & gas markets, as well as many other process industries. The Fieldbus Foundation’s annual

20  industrial automation asia | April 2008

meeting opened on Wednesday, Feb 27, with an overview of current Fieldbus Foundation developments across the globe. The programme was highlighted by end user presentations on process integrity, open scalable integration, and business intelligence. Supporting demonstrations and Q&A sessions allowed attendees to share experiences and technology insights. General Assembly presentations i n c l u d e d : R o n S c h o e m a k e r, Nederlandse Aardolie Maatschappij BV, ‘Diagnostics For OpEx: Are We Ready’; Paul Young, Ineos, ‘Life Cycle Benefits From Design To Operation’; Pico de Jager, Vopak, ‘High Availability For Terminal Logistics’; Alexandre Stephanovitch, Serbia Gas Engineering, ‘Foundation: A Complete Automation Infrastructure’; Mike Downey, Jacobs Engineering Group Inc, ‘Project Planning And Execution’; and David S Lancaster and Richard Mills, Bechtel, ‘Mega Projects: An Engineering Contractor’s Experience’. The General Assembly keynote address, delivered by Dr Norbert

Kuschnerus, president of the NAMUR Board of Management and senior vice president, Bayer Technology Services GmbH, Leverkusen, Germany, h i g h l i g h t e d t h e o p e n i n g d a y ’s welcoming reception. Dr Kuschnerus discussed how leading companies l i k e B a y e r a re u s i n g e n a b l i n g technology to continuously improve plant operations. The Fieldbus Foundation conducted its annual business meeting for members only on Friday, Feb 29. During this time, end user workshops on topics such as fieldbus engineering, implementation, and maintenance were available to attendees at ACTA (Antwerp Center for Applied Automation), a local academic institution. A technology showcase was also presented throughout the General Assembly, with major control system and instrumentation suppliers displaying the latest Foundation fieldbus products, solutions, and services. ENQUIRY NO. 2118


MITSUBISHI ELECTRIC MELSERVO J3

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Servo System Controller NETwork

Mitsubishi Electric Asia Pte Ltd Industrial Division

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2500

Even if several such transitions are initiated in parallel, there are many short waiting times that eventually slow down the machine. Each transition takes as long as the reaction time between an input signal and the corresponding output signal. If this reaction time can be shortened, the machine performance is increased. 30,00%

20,00%

ms

ms

3% Efficiency Gain

Tc = 1 5

Eg: 2 Trans/sec, from 5 ms Profibus to 0, ms EtherCAT:

22,50%

Tc = 1 10

m

s

15,50%

c1

=

2

10,00%

T

therCAT is the fastest Industrial Ethernet technology for I/O, drives and controls – this was reconfirmed recently by a research project named ‘ESANA’, which is funded by the German Federal Ministry of Education and Research. This prompts the question what kind of applications benefit from such fast communication cycle times starting from below 50 µs, and why. Or: who needs this kind of performance? In general, two types of applications can be distinguished: first the ones that use closed loop controls, such as motion control applications. Shorter control cycle times enabled by faster bus systems clearly lead to better control accuracy and thus to tighter, better control behaviour. This is pretty obvious, and can be illustrated by the measurement below where the resulting actual value of the hydraulic main axis of an injection molding machine at 2 ms cycle time was compared with the value at 0.25 ms cycle time.

ms

E

Pride

Efficiency Gain

Of the

Two types of applications benefit from fast Industrial Ethernet technology: the closed loop control type and the sequential steps type applications. By Martin Rostan, executive director, EtherCAT Technology Group

Tc = 1 20

Leader

Asia

5,50% 0.00%

T c1

0.1

0.2

0.5 1.0 2.0 5.0 No. of Transitions / sec

=1

10.0

ms

20.0

Efficiency gain through shorter cycle times. Pressure (psi)

2250

Actual value, 0.25 ms cycle time

2000 Actual value, 2 ms cycle time

Command value

1750

1500

1250 3.4

3.45

3.5

3.55 Time (s)

3.6

3.65

3.7

Closed loop control accuracy influenced by cycle time.

For PLCs But how about the second general application type, which can be characterised by sequential actions? In many PLC type applications there are so called transitions: the PLC initiates something (eg: starts a pneumatic cylinder movement), and then waits until an input signal shows the success of this step (eg: ‘end position reached’). 22  industrial automation asia | April 2008

Classical PLCs with cycle times in the order of several milliseconds and equipped with a legacy fieldbus system use a layered control architecture consisting of several subordinate (usually cyclic) systems: the actual control task, the fieldbus system and perhaps local expansion busses within the I/O system or simply the local firmware cycle in the peripheral device. The resulting reaction times are typically 3-5 times higher than the controller cycle time – an unsatisfactory solution. Equipped with EtherCAT instead, the communication system becomes so fast that its update can be executed between two control cycles. The resulting reaction time is 1…2 control cycle times, and thus substantially faster than before, without changing the CPU performance. Or, in other words, the I/O reaction time becomes as fast as with local I/O, the bus system does not add any delays any more. Therefore, even applications with classical PLC systems benefit substantially by EtherCAT.


This benefit becomes even more obvious if the classical PLC is replaced with a really fast CPU such as an IPC or PAC. These controllers provide raw processing power at little costs, and equipped with the technology they can fully materialise this advantage. Time Stamping & Oversampling The precise synchronisation provided by EtherCATs distributed clock mechanism also allows for more advanced solutions such as time stamp or oversampling I/O. All EtherCAT devices have their own local clocks, which are automatically and continuously synchronised with all other clocks via its communication. Different measurement cycle

PLC cycle

communication run-times are compensated, so that the maximum deviation between all clocks is generally less than 100 nanoseconds. Time stamped I/O data contains a time stamp in addition to the process data. This time stamp – naturally expressed in the ubiquitous system time – enables provision of temporal information with significantly higher precision for the process record. Time stamps can be used for inputs (eg: to identify the time of an event occurred) and outputs (eg: timing of a response). Oversampling enables multiple sampling of a process record within a communication cycle and subsequent (inputs) or prior (outputs) transfer of all data contained in an array. The oversampling factor describes the number of samples within a communication cycle. Sampling rates of 500 kHz can be achieved, even with moderate communication cycle times. Triggering of the sampling within the I/O components is controlled by the local clock (or the global system time), which enables associated temporal relationships between distributed signals across the whole network. Time stamping and oversampling allow for timely reaction that is much more precise than the controls or communications cycle time, and further amplify the advantage. ENQUIRY NO. 2119

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April 2008 | industrial automation asia  23


issues & insights

All Mix

Wireless Technologies:

In The

Mix multiple wireless technologies in order to create the optimal commercial wireless solution. By Joel Young, senior VP & CTO, Digi International Inc

A

s advancements in wireless technology have caused the wired paradigm to fade, and as pervasive wireless in consumer markets has driven our belief in easy, low cost solutions, there is a need to remember that commercial needs are different. Can a wireless solution in the commercial and industrial world be cost effective? Considering consumer perceptions and commercial realities, the answer now is a resounding ‘yes’. More and more today, many organisations are beginning to mix multiple wireless technologies. The different wireless technologies available today include Cellular, WiMax, Wi-Fi, proprietary RF, ZigBee and Bluetooth. With the exception of Bluetooth, all of these technologies are commonly used in commercial applications.

Martijn Hendrickx, Antwerpen, Belgium

• W-WAN There are three forms of Wireless Wide Area Network (W-WAN) technology: Time Division Multiple Access (TDMA), used in GSM and digital cellular networks; Code Division Multiple Access (CDMA), used in CDMA cellular networks; and Orthogonal Frequency Division Multiple Access (OFDMA), used for WiMAX and other 4G cellular data systems. Depending on the needs of the application, there are several key issues that must be addressed when choosing a W-WAN system. It is important to first assess what kind of data throughput, latency and quality of service is needed. Regardless of the technology, the higher the performance, the higher the cost. Depending on the plan, IP addresses are often private and dynamic, and destination routing usually does not work. Therefore, use device initiated connections or simulate an extended network using something like a VPN. Device initiated connections are critical. There are very few unlimited data plans for the non-human tethered device. However, very low 24  industrial automation asia | April 2008


issues & insights

• Wi-Fi Wi-Fi most often refers to the 802.11 family of standards. The range of standards stretches from 802.11 and 802.11a all the way past 802.11s. Wi-Fi is used mostly

Electric Drives and Controls Hydraulics

as a Wireless LAN (WLAN), but it is also used for some WANtype access. Wi-Fi is a shared bandwidth system where access is handled using a collision avoidance system (CSMA-CA) akin to an intersection without traffic lights or stop signs - it works well in the absence of traffic. The typical architecture for a Wi-Fi system is a star topology where users associate with access points. Mobility is allowed between two access points but often becomes problematic if the access points are on two different subnets. Probably the most important thing to consider when deploying Wi-Fi is that manufacturers tend to cater to consumers. Therefore, chipset vendors turn over quickly looking for the lowest cost solution which may not be appropriate for longterm commercial or industrial deployments. In addition, Wi-Fi

Linear Motion and Assembly Technologies

Pneumatics

Advancements in wireless technology have caused the wired paradigm to fade. A wireless solution in the commercial and industrial world can be cost effective.

Erkin Sahin, Ankara, Turkey

telemetry data plans are available if you know how much you are going to use. It is important to know your data needs and select a plan that allows pooling of data. Whoever the carrier might be, make sure that the device is supported and certified by its network. Just because a SIM card works does not mean that a device will connect into a network. Even the largest carriers cannot cover everywhere, and the networks most often have capacity where humans are present. So when deploying to a remote site, it may be necessary to employ extraordinary measures to get coverage.

systems are not well suited for low-power consumption. It is also necessary to match the security policy of your environment. One of the key benefits of Wi-Fi is that there are so many networks already deployed.

Service

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ENQUIRY NO. 764

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April 2008 | industrial automation asia  25


issues & insights

• ZigBee & PANs Personal Area Networks (PANs) originally were defined as a network for a very small area around a person. Over time, this definition has expanded to any wireless network that is not Wi-Fi (WLAN). Key attributes commonly associated with PANs are low power and low cost. When choosing a wireless PAN technology, there are four critical considerations: – Power: Will nodes and routers be battery powered or is there access to continuous mains power? Keep in mind that extreme low-power solutions usually have restricted range and duty cycles. – Range: How far do you need to go between RF points? This ends up being a direct tradeoff with power consumption. When travelling long distances on a small budget, 900 MHz might be best. If power is available but the location of 26  industrial automation asia | April 2008

The number of networks already deployed is usually why Wi-Fi is chosen.

Erik Araujo, Sao Paulo, Brazil

This is one of the most common reasons why Wi-Fi is chosen. Remember that the network was probably deployed with humans in mind, so coverage might not exist where your device needs it. Hence, it is a good idea to perform a site survey to understand the system’s range. Since the network is most likely already deployed, it also already has a security policy. The family of Wi-Fi related standards has a myriad of different encryption and authentication methods and as the new device on the network, it must conform to that policy. This means choosing an embedded WiFi supplier that has implemented the full range of security options. While this relates to security, it also means choosing a radio design that will be available for the long term. Be wary of consumer radios that will trigger embedded driver upgrades. The cheap radio may not actually be low cost in the end.

end points is uncertain, then a mesh network might be best. – Environment: Is it noisy or quiet from an RF perspective? Does the environment change based on time of day or other characteristics? Are there multiple equipment vendors? For example, if the 900 MHz spectrum is crowded, then a 2.4 GHz solution may be more suitable. – Data flow: How should the data flow? Does it always flow to a centralised point? Are there any latency restrictions? What are the throughput requirements? How often does data flow? For example, if data always flows to a reasonably close, centralised point, then a point-to-multipoint network may be best. Furthermore, when deploying a PAN for commercial and industrial applications, the environment should be assessed. A PAN should be used when no other infrastructure is present or when there are low power consumption requirements. Then consider the spectrum. If it is noisy, a frequency hopping or frequency agile solution is probably necessary. Even though you might be deploying an ad hoc network on the fly, it is still important to identify the RF weak spots and single points of failure. This includes assessing the

environment at different times of day. The next step is assessing practical interoperability over the air. Interoperability means more than just conforming to the standard. A standard only goes so far and almost never guarantees application compatibility. Rather, they are meant to define the level of interoperability that can be expected. Application context and provisioning are very important for a practical sensor system. Piecing The Jigsaw A practical wireless system may involve wireless components at the WAN, LAN or PAN level. The critical components in architecting a well designed system must be selected with understanding the flow of data and the type of service required. It is important to assess the endto-end functionality, level of service, location of intelligence and security levels. The question of functionality usually relates to whether the application is for logging, control, alarming or potentially all of them. Level of service involves whether the data is mission critical or best attempt. This then helps drive where intelligence should be placed. As a general rule, intelligence can be placed at the device, at an intermediate point or at the enterprise. It is generally unwise to put intelligence everywhere, and mission critical communication almost always requires intelligence at


issues & insights

first. Nonetheless, do this with an eye for potential expansion. the end device. Security should then be overlayed on top by evaluating what happens if the system is compromised from both an access and eaves dropping perspective. Determine if there are opportunities to use existing cabled communications and local power, and check for the availability of wireless infrastructure like Wi-Fi and Cellular signal strength. With the application needs determined and the available infrastructure evaluated, it is time to complete the puzzle. This involves doing an environmental assessment, site survey and considering the cost trade-offs for different deployment options.

Deploying a mixed wireless system can be complex on the environment, but also on the deployment. As such, it is important to determine how the system will be deployed over many sites. Is it scalable? Is it maintainable? Often times it is easy to get an initial system in place, but difficult to duplicate or maintain it. Guiding Principles Focus energy on high payback things first. Nonetheless, do this with an eye for potential expansion. Sometimes there is a natural tendency to build intelligence into the system at every level under the belief that it makes a more robust system. Unfortunately,

ENQUIRY NO. 2201

ENQUIRY NO. 774

Focus energy on high payback things

custom logic and filtering at too many places makes trouble shooting difficult – especially when using multiple wireless technologies. Place decision making where it is most efficient. Minimise the number of vendors and/or different technologies. Multivendor environments are often quoted as the true benefit of standards. It is important to remember that standards provide multiple vendor sources, but do not mean that mixing and matching is necessary. Too much mixing obviates suppliers from responsibility because they can always point to the other vendor. Match the network to the criticality of communications. Never try to over engineer the system. If the system communications are not mission critical, do not try to make it that way. It will add cost and complexity in the end. Finally, if you have a cable, use it! Wireless technologies are wonderful, but a short cable always works better.

April 2008 | industrial automation asia  27


issues & insights

ord utting Measures

W

ireless is the buzz, but beyond that buzz, there’s engineering effort needed to develop an industrial strength wireless network with assured security, redundancy, availability and expandability. Wireless sensors have existed for many years. Thousands have been successfully deployed in many challenging applications. These sensor networks have not only saved cost by eliminating wiring, but have enabled applications that have challenged the wired world. Wireless in the industrial infrastructure is an enabler to what wireless has to offer. This is not simply for cost savings. In some cases, there are additional costs associated with planning and installing antennas. But wireless can create significant business opportunities, provided the design is sound. 28  industrial automation asia | April 2008

The key to building an industrial wireless infrastructure is coordination and support; it is important to have an industrial wireless partner that can address all the issues from sensor network through wired interface and Wi-Fi solutions. By Anthony F Porrazza, product manager, wireless, Honeywell Process Solutions

Wireless Infrastructure A starting point for industrial wireless can be as simple as the wireless retransmission of analogue or digital points back to a wired analogue input or output. On the other extreme, one could have an Ethernet connection of many points and diagnostic information all brought back to a central control system. The first application is a simple application of wireless requiring in some case only a base radio receiver and wireless devices. These devices can be locally configured and do not require a computer. The base receiver provides analogue or digital outputs that may be directly wired into a monitoring and control system. In this type of system very little, if any, infrastructure is required. Considerations need to be made to the operating frequencies and radio

protocols. These implementations have limited security, expandable to some fixed limit determined by the capacity of the base radio receiver and offer little or no redundancy and limited diagnostic information. This is sufficient for many applications and has been successfully implemented in hundreds of applications with many hundreds of devices. Sensors networks have been expanded to provide some limited redundancy and range extension, but there are significant tradeoffs and installation considerations. Taking wireless to the next level re q u i re s m o re t h a n a s e n s o r network. Any consideration of wireless implementation beyond simple applications must begin to address the comprehensive wireless infrastructure. Ultimately, wireless access to the


issues & insights wired world provides the avenue to an expanding array of enablers and solutions. The key factors in the design of an industrial wireless infrastructure are the following: • Scalability • Reliability • Security Scalability Solution J u s t a s t h e ‘ w i re d ’ i n d u s t r i a l infrastructure is designed to support many different applications, so too must the wireless infrastructure. Wireless as previously outlined goes beyond sensor networks and must be designed to address the rapidly changing wireless landscape. It must also be robust enough to support the growing number of applications and standards. Industrial wireless scalability is best addressed by an infrastructure approach. In the wireless world we are now faced with radio frequency and bandwidth issues that are not factors in the wired world. Co-existence with

existing wireless deployments and the ability to allow for new solutions need to be primary concerns. To accomplish this, an architecture combining multiple frequencies, bandwidths and protocols is necessary. Infrastructure devices may comprise of multiple radios and multiple access scenarios to provide for the greatest flexibility. A high speed, high bandwidth wireless backbone is essential to provide this avenue. The design should be an open system that allows connection to any plant system and inherently transports existing protocols. It must also be able to provide wireless remote access for a number of wireless and wired devices and their supporting applications. Therefore, an infrastructure that combines sensor radios, wireless Ethernet and remote wired Ethernet and Wi-Fi access should be part of any industrial wireless infrastructure design. A robust wireless infrastructure must also provide bandwidth flexibility

The goal is a single open, standardsbased, upgradeable industrial network that can reduce risk and associated support cost.

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April 2008 | industrial automation asia  29


issues & insights not only to conform to countr y restrictions but allow for the optima utilisation of bandwidth. Infrastructure members that allow the use of multiple radios best accomplish this and allow for any future developments in radio technologies and standards. Reliability Issue Reliability is affected by many factors such as co-existence, redundancy and availability. What is becoming more and more common today is addressing legacy wireless in the infrastructure. These outside sources may cause interference or may need to co-exist. An industrial wireless infrastructure must support co-existence and make the best use of limited spectrum. This often is handled by assessing the site to determine what wireless spectrum is in use and what is available and configuring the infrastructure hardware to assure reliability for site wide use. To ensure reliability, an industrial wireless infrastructure must include redundancy. It must be able to handle multiple hardware failures with no degradation in performance. This is best accomplished by ensuring redundant communication paths forming what is known as a mesh. This communications mesh assures that sensor and system communications have multiple paths to relay information to the wired world. The most reliable designs have sensors in parallel communications on at least two paths. If either of the paths is interrupted, the parallel p a t h p re v e n t s c o m m u n i c a t i o n disruption. A robust design also utilises a powered mesh infrastructure to assure availability with fast mesh reformation and no significant loss in performance as the wireless system expands. Power management on the sensor level is also extremely important. Deterministic power consumption and alerting of battery levels assures long life and planned availability of sensor data. The design should also ensure that sensor traffic is given dedicated bandwidth on the high speed 30  industrial automation asia | April 2008

Robust security should extend to the sensor level by utilising advanced security deployment methodology.

backbone to insure no degradation and the infrastructure supports more and more applications. Network Security End-to-end security is essential in the design of an industrial wireless infrastructure. Security begins with the integration of the gateway to the wired infrastructure through to the secure commissioning of sensors. A n y w i re l e s s i n f r a s t r u c t u re device should accommodate the latest implementations of network security for replay protection, source authentication, resistance to denial of ser vice attacks and security key deployment and management. Robust security should extend to the sensor level by utilising advanced security deployment methodology. To summarise, the design must create a network that will: • Send data reliably and when needed • M e e t a l l p l a n t s e c u r i t y requirements

• Handle multiple types of devices from a few to thousands • P ro v i d e p re d i c t a b l e p o w e r management • Handle multiple applications and protocols • Address present and future network utilisation • Provide end to end security Finally, the key to building an industrial wireless infrastructure is coordination and support. Beyond providing hardware that fits the industrial environment, it is important to have an industrial wireless partner that can comprehensively address all the issues from sensor network through wired interface and Wi-Fi solutions. Preferred is a single source partner that is equipped to evaluate, design, implement, monitor and assist in expansion of the wireless infrastructure. The goal is a single open, standards-based, upgradeable industrial network that can reduce risk and associated support cost. ENQUIRY NO. 2202


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Multiplying Your Performance An advanced and high-speed motion control system enables OEMs and system integrators to enhance the flexibility and performance of their end products. By Philip Tang, sales engineer, Mitsubishi Electric

T

oday’s global market, especially in the semi-conductor industry, requires not only better CPUs to boost the functionality, performance and cost efficiency of components, but also higher throughput of the entire system. A high performance motion controller with multiple CPU high-speed transmission will be able to fulfil these goals. High-speed Transmission Multiple CPU high-speed transmission refers to a data transmission function executed between multiple CPUs at a fixed cycle. In the data transmission of a conventional motion controller, the device data on the motion controller side is set in the shared CPU memory at the main cycle intervals of the motion controller, and then fed to the programmable controller by the END processing in the sequence programme. On the other hand, with a multiple CPU high-speed bus, the data is 32  industrial automation asia | April 2008

transmitted to the programmable controller at the multiple CPU highspeed transmission cycle and read out by the sequence programme, by setting the device data on the motion controller side to the shared CPU memory. As a result, the device data is updated at high speed without the influence of the motion main cycle or the scan time of the sequence programme. The conventional motion controller uses only the system bus for data transmission between all units. Consequently, as the number of units increases while large volumes of data are periodically transmitted between CPUs, the required data transmission time inconveniently increases. On the other hand, a multiple CPU high-speed bus exclusively used for transmission between the CPUs enables high-speed data transmission regardless of the number of CPU units or volume of data. With this multiple CPU high-speed

bus, large volumes of data up to 14kW are refreshed at high-speed transmission cycle to allow high-speed data sharing between the CPUs, thereby increasing the data volume to almost 3.5 times the conventional transmission. Synchronised Data Transmission Since the multiple CPU high-speed transmission is synchronised with the operation cycle of the monitor controller, data transmission involves no inefficient latency. In addition, data transmission on the programmable controller is also synchronised; synchronised data transmission is secured between the programmable controller and the motion controller. Furthermore, since the communication with the ser vo amplifier is synchronised with the operation cycle of the motion c o n t ro l l e r, s y n c h ro n i s e d d a t a transmission is achieved throughout between the programmable controller,


control point

Sequence Instructions A free area is newly provided in the shared CPU memory. In this area, the user can specify the same devices in the sequence programme, motion sequential function chart (SFC) programme and servo programme and easily understand the interrelationship between the programmes, thus improving the programme readability of the system. Sequence instructions for the

motion controller only are modified so that ‘complete device’ or ‘device for storing complete status’ can be omitted. This improvement simplifies sequence programme execution while motion controller instructions are being used. On the other hand, conventional motion controller can perform sequence instructions for the motion controller only once during a scanning operation. With this new series, multiple sequence instructions for the motion controller can be executed at the same time (a maximum of 32 times per single scanning operation). Interrupt sequence programmes synchronised to the operation cycle of the motion controller can be described; sequence processing synchronised with the motion control is now available. As a result, the high-speed servo control function uses information received from the units under the control of the programmable controller (high-speed counter module and

The hardware architecture of the new generation of motion controller has been significantly improved.

analog-digital converter module) and the information can also be used in various applications mainly related to the sequence. The hardware architecture of the new generation of motion controller has been significantly improved compared to the conventional ones. Performance is almost doubled and an operation cycle of up to 0.44ms every six axes can be realised. The processing speed of motion SFC instructions has also been increased to almost three times that of the conventional series on a 32-bit addition basis. ENQUIRY NO. 0432

ENQUIRY NO. 775

motion controller, and servo amplifier. Thus, the data transmission has no latency and can process the data at high speed, resulting in a remarkable reduction in tact time. Refresh device range settings are now increased from four types to 32 types for more flexible setting of the command and monitoring devices between the CPUs. As a result, the user can assign devices as desired, increasing the degree of freedom in programming.

April 2008 | industrial automation asia  33


control point centre configurations. Combined with power monitoring system, PLCs and lighting control systems, AC drives are vital components of the facility automation solution. The advantages associated with the usage of AC drives are: • Reduced energy costs • Lower machine speed and wear • Matching machine output to HVAC load requirement • Lesser dependence on mechanical flow deverters in systems design • B e t t e r t e m p e r a t u re a n d a i r exchange regulation Case Study CTS Corp is a designer and manufacturer of sensors and electronic components, and is also a provider of value-added electronics manufacturing services (EMS). Their clean room systems used different technologies for individual systems to have a combined energy savings. Altivar 61 variable speed drives (VSD) with a built in KWH meter were used on their chilled water pumps, condenser water pumps, air handling units (AHU) and central exhaust fan systems. Especially for the AHU, temperature sensor was used to provide feedback to the VSD to regulate the air flow to maintain the required temperature inside the clean room.

Amplifying Efficiency An adjustable frequency AC drive allows the user to effectively control motor output speed; matching output of motor to equipment load requirements eliminates wasted power usage. By Schneider Electric South East Asia HQ

H

VAC systems modify temperature by passing air over heated or cooled surfaces and circulate air through the facility. Devices used in the process may include fans for both supply and return air, pumps for chilled water distribution, cooling towers, chillers and boilers. Often motors that run these devices operate at full speed and the system uses dampers and valves to control air and water flow. This is not an efficient use of energy. However, if AC drive is installed, the overall system performance will improve and energy consumption will be reduced because the fans and pumps now have variable torque loads. Customer Benefits When variable torque load is used, the horsepower needed to drive the load changes with its speed. As the speed of a load is reduced, the power required to drive it decreases as a cube of the speed. At 80 percent speed, only 51 percent of full load power is required 34  industrial automation asia | April 2008

to drive the fan or pump. These energy saving drives are easy-to-use and safe to operate, economical and diagnostic, powerful and flexible. AC drives are available in custom enclosures and in motor control

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software & networks

Priority Wireless Networks:

Security

Wireless networks introduce significant security concerns as enterprises must not only protect their data and networks, but must also address a growing number of regulatory requirements for data safeguarding. By Peter Rysavy, president, Rysavy Research

hile any organisation wants to protect its sensitive data, to detect tampering of data and to limit access to authorised individuals, various industries must also comply with an array of regulatory and industry requirements and guidelines. 36  industrial automation asia | April 2008

One common requirement, especially for government organisations, is that sensitive data that is stored or communicated over public networks must be encrypted using certified algorithms. Another common requirement is for users to authenticate themselves

using two-authentication, generally achieved by a combination of something the user possesses such as a security token, and something the user knows. Organisations designing new mobile access solutions need to plan accordingly to ensure they comply with both current and future requirements. Security Issues In the case of user authentication, network operators are primarily concerned with fraudulent use of their network, and so the authentication mechanisms are designed to ensure that only legitimate devices connect to the network. With Global Systems for Mobile Communications (GSM) networks, for instance, the network validates the credentials in the Subscriber Identity Module (SIM) card. In 2G cellular networks, there are no provisions to authenticate the network to the user system. This allows man-inthe-middle attacks where an attacker could operate a low power equipment that simulates a wireless network, and could acquire user credentials.


software & networks While this is not a trivial undertaking, cellular technologists considered it a sufficient threat that 3G technologies such as Universal Mobile Telecommunications System (UMTS) employ bidirectional authentication. The problem, however, is that users usually do not know whether they are on a 2G or 3G system, especially as operators have implemented seamless handover for both voice and data services between their 2G and 3G networks. The handover allows active data sessions to originate on one network, and then to carry across to the other network with the same IP address. This problem of 2G vs 3G systems is also an issue when we look at encryption. With respect to user authentication, some mobile devices (GSM/UMTS), allow for devices to be configured so that a user must enter a PIN before using the device. However, a user can easily disable this mechanism. It also does

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not satisfy two-factor authentication requirements. There is an additional concern with respect to authentication, particularly if the customer has arranged for a private connection between their network and the operator network. Typical arrangements include network VPNs and Frame Relay circuits. Often, these custom arrangements are made in conjunction with a specific pool of IP addresses that the network assigns to mobile systems, facilitating firewall rules at the customer site.

The vulnerability is that access is based on the device’s credentials, not the user’s credentials. If the user’s network card, laptop or smartphone is lost or stolen, then in many circumstances it will be possible for a third party to gain access to the enterprise network via the private connection. The primary security mechanism promoted by operators is their encryption of the radio link. 3G systems have indeed implemented robust measures, with both UMTS2 and CDMA2000 Evolved Data Optimised (EV-DO) technologies having implemented 128-bit encryption algorithms: Kasumi for UMTS and Advanced Encryption Standard (AES) for EV-DO. Security Limitations There are, however, various limitations to these schemes. One is that they are only available when in 3G mode.

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April 2008 | industrial automation asia  37


software & networks

Marc Swarbrick, Nottinghamshire, United Kingdom

except in isolated instances where the operator operates both the wireless network and the alternate network. Does this mean organisations should not take advantage of the operators’ security options? Not necessarily. These security options may well augment an overall security architecture. For instance, some operators provide firewall configurations that prevent unsolicited IP packets from being sent to mobile devices, thus protecting against denial-of-service attacks. But by themselves, the operator provisions do not fully address the needs of secure applications. End-To-End Security The only approach that provides security that addresses both regulatory requirements and guidelines, and that also overcomes the shortcomings of just using an operator’s security provisions, is a virtual private network (VPN) that extends from the user device to a controlled node within the customer organisation’s network. By using an end-to-end approach, organisations achieve the following security benefits: • Two-factor authentication • Mutual authentication • Protection against lost or stolen devices • Protection regardless of access network • Privacy at every point of network traversal • No need for customised back-end connectivity arrangements with operator

If a network card, laptop or smartphone is lost or stolen, then it might be possible for a third party to gain access to the enterprise network via the private connection.

especially as it is completely out of the control of the organisation using the network. Then there is the matter of backend connectivity, which refers to how organisations connect their networks to the operator network. The default connection method is via the Internet, which clearly is not a secure medium. To augment security of this link, some operators offer connectivity options such as Frame Relay permanent virtual circuits (PVCs) and network VPN connections. However, both Frame Relay and network VPNs require custom arrangements with the operator, and will incur additional service charges. And they still do not address the problem that the data will pass through an unencrypted stage within the operator network. Finally, users may be using a number of different access networks in addition to a cellular operator wireless data network. For instance, they may want to use their home high-speed Internet connections, hotel broadband connections or public hotspots. Clearly, the operator based security mechanisms will provide no benefits in these alternative connection scenarios

ENQUIRY NO. 2303

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For back-end connectivity, the default connection method is via the Internet, which clearly is not a secure medium.

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Another concern is that cellular operators do not necessarily employ radio encryption even when it is available, as it is an optional feature of many wireless technologies, even 3G systems such as EV-DO. Your home operator could offer the encryption, but you might roam onto another carrier’s network that does not have encryption. Even if you could restrict operation to wireless coverage areas that have strong encryption, there is yet another security concern. This is that the radio encryption terminates within the operator network. For EVDO networks, the encryption end point is at the base-station controller (BSC), whereas for GSM/EDGE/UMTS networks it is at the Serving GPRS Support Node (SGSN). Beyond that, the data typically is in the clear as it traverses the operator network. Even if the operator re-encrypts user data within their network, the data will exist in an unencrypted form in a part of the network. Granted that the unencrypted data is on the operators private network and would likely be difficult to access from the outside, but relying on the operator safeguarding sensitive data represents a significant vulnerability, 38  industrial automation asia | April 2008


software & networks

Physics Of

Structural Automation The interlacing of open standards results in the entire building being networked. By Citect Global Communications

T

he Einstein III building in Haidhausen, Munich, was erected in 2000. Named after Germany’s most famous scientist, the building offers 37,000 sqaure metres of office and commercial space and is owned by Hypo-Vereinsbank. Amann GmbH was challenged with providing an integrated building automation solution with an intelligent, scalable architecture that uses open standards to meet the requirements of a dynamic enterprise. In addition, the solution would have to supply reliable individual comfort for the tenants while providing energy and cost savings. The Solution Amann developed a complete building automation solution that combines the highly scalable architecture and open standards of CitectFacilities with the European Installation Bus (EIB) and BACnet. The interlacing of these open standards resulted in the networking of the entire 40  industrial automation asia | April 2008

building. Einstein III offers all the conveniences of a modern, working office environment. An unmistakable characteristic is the glassed rotunda that holds the management offices and conference rooms. The building exterior has motorised, external sun protection blinds. The blinds on each facade are controlled centrally through CitectFacilties or independently via sundirection and wind sensors. The interior fittings are also designed to meet the requirements of a dynamic enterprise, which i s c h a r a c t e r i s e d b y f re q u e n t reorganisations of the room layouts. The system provides tenants with consistent individual comfort. For example, all areas are equipped with cavity floors for flexible wiring, daylight-dependent lighting for workstations, as well as energyoptimised heating and ventilation. CitectFacilities controls the automation aspects of the building, such as external blinds, lighting,

chillers, air handling units and the heating circuits through centralised control stations. BACnet The BACnet standard has been developed by builders and equipment manufacturers as an open standard for building management. BACnet is now a powerful tool for the unification of all building-related automation services and can be implemented over standard communication medias, such as Ethernet.

Complete visualisation of a conference room.


software & networks The assigned controllers in the different substations of ventilation and heating communicate over Ethernet with BACnet objects. Altogether, approximately 6,000 EIB group addresses are used for visualisation on the system. The advanced server/ client architecture of the system means only the server requires a bus coupler to BACnet. The system leverages EIB and BACnet for flexible building automation. During the last couple of years, the European Installation Bus (EIB) has become accepted as a prominent standard for building automation in Central Europe. It offers a large selection of compatible products from different vendors, as well as a standardised, easy tool to configure the system. I n o rd e r t o m a k e a l l d a t a accessible, all EIB communication links are coupled via EMWS gateways from Amann to the BACnet network. This allows each office to control building aspects such as lighting and temperature. This increases building efficiency, which leads to

energy and building maintenance cost reductions. In the rotunda, the areas were equipped with an additional airconditioning unit. Fans for each sector look after ventilation, heating and cooling. Einstein III is the first building in Germany with the ability to independently control these environmental conditions in each room, using native BACnet DDC controllers. Flexible & Scalable “The experience of the projects with BACnet implemented to adhere to the BACnet standards and appropriate i n t e g r a l p l a n n i n g , p ro v e s t h e integration of the different technical plants is simplified tremendously,” says Marc Voss, technical manager, Amann. M r Vo s s i s c o n v i n c e d t h a t buildings owners and companies will see Einstein III as the example to follow and will begin to use open standards. CitectFacilities, EIB and BACnet combine to provide an open, scalable,

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intelligent building automation system that offers comfort and energy efficiency throughout the building, while significantly lowering the lifecycle costs. Furthermore, EIB and BACnet give the client the flexibility to purchase additional control equipment from any vendor for further developments, while the scalability of the system allows the system to grow to meet the client’s needs. ENQUIRY NO. 2304

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SATELLINE radio modems are used e.g. in materials management, access control and alarm transfer. SATEL specialises in the design and manufacturing of wireless data transfer devices. SATEL products are used in demanding wireless data transfer systems all over the world.

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ENQUIRY NO. 780

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April 2008 | industrial automation asia  41


instrumentation & Measurement

e v i t c e EffPump Monitoring Integrating continuous online pump monitoring with the plant’s control system to increase asset availability and prevent lost profits through unplanned downtime. By Jonas Berge, senior PlantWeb consultant, Emerson Process Management

V

ibration monitoring is no longer important just for big ticket assets such as turbines and compressors. Motor-pump trains, which service other expensive assets, can halt production if they fail. Fortunately, a fault analysis algorithm for centrifugal pumps, used in combination with Foundation fieldbus and Electronic Device Description Language (EDDL) enables efficient pump monitoring to increase plant up-time with less effort. Many problems can be missed during the occasional field check for pump vibration. Continuous pump monitoring that reports asset health data to technicians and operators can reduce pump failure and plant downtime. Plant Challenge Motor-pump machine trains are the backbone of most process industries and account for a large part of the plant’s rotating machinery. Many are essential to maintaining critical production processes. Problems such as bearing wear, shaft misalignment, pump cavitation, imbalance, 42  industrial automation asia | April 2008

motor overheating, and overloading can cause a pumpmotor train to fail and stop production. In the past, many plants at best inspected pumps infrequently because they had to be done manually in the field. In situations where pumps are not operating, no condition monitoring data can be collected. Even if online vibration monitoring was used, it was not sufficient to detect problems such as overheating or overloading, or to conclusively determine what was wrong with a pumpmotor train. Most vibration monitoring software has to run on a separate workstation from the plant control system. This works well for one or two package unit assets such as compressors or turbines, which have their own control systems, but using specialised software becomes unwieldy when monitoring numerous pumps. Operators and technicians need the ability to monitor pumps, transmitters, and valves from a single software application. New Solution Specialised machinery health transmitters monitor the health of AC induction motor-driven centrifugal pumps allowing integrated, continuous monitoring. This optimised machinery health solution is in a rugged enclosure for field mounting and is ideal for pump applications where turbine monitoring would be more than is required. This new transmitter makes pump monitoring continuous and automatic instead of infrequent and manual. The device is mounted next to the pump, minimising sensor


instrumentation & measurement wiring. It communicates asset health information to the control room, reducing the need for field inspections. In addition to six vibration sensors, the transmitter also measures motor flux, temperature, and shaft speed. These additional measurements enable more complete and accurate diagnosis of developing problems. Software in ordinary computers cannot process the hundreds of samples per second collected during vibration monitoring. But diagnostics analytical technology embedded in this machinery health transmitter recognises the symptoms that signify potential problems and quickly communicates them to the plant’s control system. This specialised technology continuously assesses motorpump train health based on all inputs, produces a health index that summarises detailed diagnostics into an easily understood indicator of overall asset health, and recommends the necessary actions to address any problems.

Overview of pump assembly health.

Tightly Integrated Field data diagnostics collected through a digital plant architecture is the foundation for predictive and efficient maintenance management and leads to improved plant performance. Detailed diagnostics are communicated to the technician’s device management software using Foundation fieldbus, which is also employed for its initial setup and configuration. The machinery health value and other key indicators are available as Analogue Input (AI) function blocks. They can be trended in the control system and compared to process variables such as temperature, pressure, or flow to detect correlation between pump health and operating conditions. Once the operator is aware of a pump condition such as cavitation, the problem may be reduced or eliminated by a simple adjustment. The content and organisation of the detailed diagnostics as they appear in device management software is decided by a machinery health transmitter using EDDL technology and is displayed consistently in any control system. The IEC 61804-3 EDDL standard is the key to interoperability, ensuring no functionality is lost and that all diagnostics are accessible.

Detailed diagnostics for each component.

EDDL was developed through a cooperative effort between Fieldbus Foundation, HART Communication Foundation, Profibus Nutzerorganisation eV (PNO), and OPC Foundation. Foundation fieldbus has a unique ability to send alerts to both operations and maintenance personnel. The machiner y health transmitter and some other Foundation fieldbus devices have the additional ability to prioritise alerts and show the technician which pumps have problems and which do not so they can work on the most critical problems first. Ease Of Use The machiner y health transmitter communicates diagnostic results for decision-making. EDDL presents t h e re c o m m e n d e d a c t i o n t o b e t a k e n t h ro u g h illustrations and rich graphics based on know-how from manufacturer experts.

EDDL recommends action based on manufacturer know-how.

The bewildering amount of diagnostics sent from a sophisticated machinery health transmitter is organised logically by EDDL and displayed in a user friendly way, using a hierarchical tree, tabbed cards, pop-up windows and frames, making the pump assembly easy to troubleshoot on any control system. April 2008 | www.iaasiaonline.com  43


INSTRUMENTATION & MEASUREMENT

Images assist in troubleshooting.

These intuitive graphical displays include images to pinpoint the location of the fault, needle gauges for overall health index, bar graph for cavitation and imbalance, and waveform graph for vibration spectrum. As problems occur with motor, coupling, or pump, the schematic diagram changes dynamically to indicate the problem area. The user-friendly interface allows the technician to drill down into more detail for each part to determine the problem.

The graph visualises waveforms such as a vibration spectrum.

EDDL allows technicians to use a single software application to diagnose pumps, control valves, radar level transmitter and variable speed drives, reducing the number of programmes they need to know. Enhancing ease of use even further, pumps appear on the screen with the same look and feel as other plant devices. The tools for pan and zoom of the vibration spectrum are the same as those used for any graph or chart and for any device by any manufacturer using any communication protocol for diagnostics or setup. This consistency makes the EDDL-based software very easy to use. No other technology and no amount of styleguides can provide this level of consistency. Operators are responsible for the production process and schedule, which sometimes means allowing pumps to operate beyond nominal capacity. By routing alerts to 44  industrial automation asia | April 2008

the operator workstations, operators understand how changes in operating set points can positively or negatively impact pump health. Moreover, anytime there is a pump alert, the operator can click to see the pump diagnostics, which enables decision making about the processes and maintenance. Without this feature, operators would have to switch between different systems. Experience shows that when there are different workstation requiring separate logons, etc, the diagnostic system will fall into disuse and predictive maintenance practices will end. Because an EDDL file is not software, this third-party device vendor file does not interfere with the run time robustness of the control system and enables complete integration of the device management software. The device manufacturer’s experts created online help for all parameters and wizards. This support assists technicians with the interpretation of diagnostics and guides them through determining the appropriate actions to address problems. Help is available by clicking on the parameter in question. The device management software also makes the full manual available online. Implementation Best-in-class plants predict and avert the break down of vital pumps by using machinery health solutions and reduce maintenance cost and process upsets by delivering accurate, actionable information to the right person in time to make a difference. Through this predictive maintenance approach, pump overhauls can be undertaken only when the need is supported through accurate asset health diagnostics. Those plants that had the vision to invest in Foundation fieldbus infrastructure can easily adopt this new breed of devices. If you are planning a project now, use fieldbus to build a digital plant architecture that will enable pump monitoring and other innovative solutions. Even in a plant without Foundation fieldbus, it is possible to connect several machinery health transmitters to a fieldbus interface module that acts as a gateway, allowing data to be integrated into legacy systems. In these plants, this is a good way to evaluate both pump monitoring and fieldbus technologies. Other bus technologies require undue variable mapping and other device integration technologies cannot be used on operator consoles. This new opportunity for integrated online monitoring of pumps provides plants the ability to monitor critical pump health and attain control over the plant processes, and profitability, like never before. ENQUIRY NO. 2401


ENQUIRY NO. 763


sector spotlight

F

elsomat GmbH & Co KG, a German a u to m o b i l e m a n u f a c t u r i n g company, has developed from a newcomer to the industry to a fixed entity in the global market in a relatively shor t time. CEO Helmut  F  Jäger’s goal is to offer customers added value in the form of higher productivity. Felsomat tries to realise this goal primarily through optimum utilisation and availability of the production resources and by developing careful analyses of the overall process and focusing on the essential. One of the business qualities of the creative pioneer is to detect the direction in which the wind is blowing. Said Mr  Jäger: “I believe

that the extent of automation, the purely automated loading and unloading of production machines and the part transfer in between, is for the most part exhausted.” Modular, Standardised, Flexible This is the reason why focus has been for quite some time on a strategy of better organising the entire process chain to minimise unproductive downtimes and idle periods, for exa mple, due to cycle times of d i f fe re nt le n g t h s, lo n g ro u te s of tools a nd equipment, or unproductive or nonproduction times of workers. The goal consists of more productivity with fewer machines on less space with higher quality.

The Product of

Process A strategy of better organising the entire process chain to minimise unproductive downtimes and idle periods provide a great rationalisation potential in the future. By Klaus Langanke, sales representative, Siemens AG

46  industrial automation asia | April 2008

CEO Helmut F Jäger has been outlining the highly successful path of Felsomat for many years.

Mr Jäger lists comprehensive modularisation among the chief prerequisites for achieving this goal. This is necessary to be able to adjust the constellation of production resources quickly and flexibly to different requirements (‘quantityflexible’ or ‘investment-flexible’). Another prerequisite consists of the consistent standardisation and harmonisation, primarily for automation, control, and handling, in order to make it as easy as possible for the user to respond to the need


sector spotlight for maintenance or service as part of the daily production flow. Focus On Nonproductive Times “A requirements-based, adapted degree of automation is still able to deliver a lot of advantages but we feel that the processes themselves provide a greater rationalisation potential in the future,” states the CEO. Felsomat has taken appropriate action some time ago and focused on additional logistics optimisation as well as processing technologies and the in-house development of machine tools. The hard fine turning of powertrain components was the starting point. This process usually requires clamping of the part and shorter cycle times so that nonproductive times usually have a significant effect on productivity. Further developments, especially in the area of cutting materials, drive technology (dynamic), and in part also machine technology, allows for significantly higher machining output than just a few years ago. Parts that previously required two minutes machine-running time are today machined in 30 to 40 seconds so that nonproductive times of up to 15 seconds increasingly thwart the productivity advantage, which in turn must be compensated with a higher number of machines (equaling more space and higher investment volumes). Felsomat responded with the precision turning centre FTC 180 used to machine gears, named by the company ‘productive-time machine.’ The mechanical concept of this machine is based on three simple, extremely rigid main components: A monoblock machine bed and a traveling column, both made from cast mineral composite, as well as the equally rigid tool holder. Siemens mechatronic support service simulated and optimised the interplay between mechanics and electronics of the machine prior to its use and seriesproduction. Contrary to many universal pickup machines that travel distances of up to one metre for changing a tool,

the travel paths of the FTC 180 are deliberately designed to be short so that the machine is operational again in less than one second after the productive-time parallel loading. While one spindle machines highly dynamic and precise, the other can be gently stopped after the last machining step, unloaded, the clamping device can be cleaned, reloaded, and brought up to speed. This is made possible through the cleverly fine-tuned machine geometry and constellation as well as a creative safety door concept. The Sinumerik integrated safety concept ensures the highest level of safety even when using only manual cell loading and unloading. The machine maintains fully automated loading and unloading with an integrated swing loader, combinable with a modularly expandable workpiece handling organisation module adapted to the requirements. Acting In Concert The FTC 180 as well as the automation/ handling system is equipped with their own NC Sinumerik 840D sl control system made by Siemens. The ‘solution line’ features control functionality always completely integrated into the modular drive system Sinamics S120, which enables highly compact, modular, and exactly scalable installations adaptable to the respective requirements due to its book-size system architecture.

Top to bottom: Kinematic transformations ensure optimised, space-saving travel paths and simplified programming of the portal swing loader. Turning cells and automation/ handling are each controlled by a Sinumerik 840D sl with the system architecture of the drive system. Comfortable standard for controlling and monitoring the turning cell is provided with the machine control panel.

April 2008 | industrial automation asia  47


sector spotlight

Separate control masks are implemented for the handheld HT8 terminal embedded into the HMI of the NCU.

The distribution of intelligence ensures a simple coupling as well as the perfect interplay of the core components regardless of the situation or circumstance. It also provides uncomplicated adapting to different production situations. Separate controls also provide an advantage when it comes to machine availability because this means production can continue even in case of possible automation malfunctions. Felsomat intends to link the individual machine controls via Profinet CBA (component-based automation), which enables deterministic data exchange at cycle times of 10 ms and with that even shorter response times. These short cycle times of the controller-tocontroller communication is achieved by utilising the real time functionality of Profinet. Linking the machine tools of the system with one another and with the handling units provides a clear advantage compared with previous Profibus solutions and represents another step in the direction of further reducing nonproductive times. An NC-controlled portal swing loader was designed to keep installation 48  industrial automation asia | April 2008

area and height small. The swivel axis prevents projecting movements across the z-axis and optimises travel paths. The ‘handling transformation p a c k a g e ’ i s c o n t ro l l e d b y being implemented into the Sinumerik 840D sl. This software package provides all required functionalities and assumes the kinematic transformation of workpiece coordinates to axis movements. This significantly simplifies programming for the user. The smallest SinumerikNCU (710.2) is able to control up to six axes and is delivered with integrated control functionality (‘HMI embedded’). Felsomat is equipping the handling system for the loading and unloading of the turning cell with an additional handheld Sinumerik HT8 terminal (standard equipment). An emergency-stop push button and two enabling switches (left- and right-handed use) are integrated as well. These switches have two channels to permit working within the hazard zone of a machine. The machine builder has taken advantage of the openness of the Sinumerik

world and created and implemented separate control masks for the control device. The HT8 acts as a Thin Client to use Ethernet to access the HMI embedded in the NCU, visualise current process information at the local site, and to transfer control actions (eg: during axis teaching) directly to the control system. Proven Process Capability Various projects of almost all wellknown automobile manufacturers and suppliers without exception feature a significantly improved process capability while delivering significant cost-per-unit reductions when operating the ‘productive-time machine’ during demanding non-stop usage. The machine builder reports an overall positive response with some of the potential buyers already deciding to forego all other machines. Few are willing and able to miss out on a workpiece output increased by up to 40 percent with the same or even significantly improved quality - halved tolerances and roughness depths reduced by several factors.

The travel paths of the FTC 180 are deliberately designed to be short.

ENQUIRY NO. 2402


ENQUIRY NO. 746


in business

P

artnership with its customers for m s a n i nte g ra l p a r t o f Yokogawa Engineering Asia’s objectives under the helm of Dr Tony Lee, its group president and MD. In a rapidly changing and highly competitive environment, it is no longer about technology, but more importantly, it is about helping people get their jobs done right, he said in an exclusive interview with IAA during Yokogawa’s launch of The N e w Te c h n o l o g y Pl a t fo r m Fo r Operational Excellence, in early February this year. “To help them more, we have to understand their needs and valueadd our services to them. This is where Centum VP comes in – to assist further – with their plant’s

performance. We have to develop our people (in services and solutions) to meet our customers’ needs and deliver the value-add required.” In this area, Yokogawa has spent a considerable amount over the past year on the recruitment and training of more than 100 engineers in order to meet the company’s customer-centric mindset and objectives. Upon the Centum VP system’s release, Yokogawa will be able to send these trained operatives out to solely assist its customers to fully maximise the capabilities offered by the system. “Other manufacturers sell hardware, but we deliver greater value to our customers by providing expert and support services to ensure their plants run safely and smoothly,” Dr Lee pointed out. Expansion & Extension To maintain and ultimately expand its leadership position in industrial

automation, Yokogawa will be making strides in several new markets, territories and initiatives. Besides the stalwart vertical markets of the oil and gas industries, new areas like pulp and paper, waste and water treatment have piqued their interest considerably. At present, the majority of the business comes from the chemicals, oil and gas (hydrocarbon) sectors. The intent, according to Dr Lee, is to maintain and strengthen the core business while aggressively developing and growing the smaller sectors substantially. Expansion is a definite priority for the company as it gears up to fulfil its vision of becoming the leading industrial automation player by 2010. Hot on the heels of the opening its regional HQ in Singapore in July last year, the company will be unfurling its flag in the Asean countries of Malaysia, Thailand, Indonesia and Vietnam in the near future.

Partnering For

Success

The launch of Centum VP adds to Yokogawa’s intent of climbing to the top of the industrial automation arena by expanding not only in South-east Asia, but in Europe and the US as well. By Eileen Chan

50  industrial automation asia | April 2008


in business “In Vietnam, we are looking at an engineering resources centre to serve the South-east Asian region. This resource centre can also be used to extend our services worldwide eg: for various oil, gas and power projects in other parts of the world such as Russia, etc,” Dr Lee added. While Yokogawa does not have a direct presence in Pakistan yet, the company intends to involve itself heavily in growing markets such as in the gas, chemical and fertiliser markets in the not too distant future.

Integrated Production Control System

D

“We need to push beyond Asia too. For example, for countries like Australia, where we are strong in power and mining, we intend to strengthen it further,” he said. “Infrastructure building forms the backbone of growth for Yokogawa, but in order to be more balanced, we have to develop other areas of growth,” continued Dr Lee. Going Forward… If he had a crystal ball and could pre d ic t ‘a re a s o f g row t h’ t hat companies should keep an investment eye on, Dr Lee predicts power and energy is it. He expects demands from these areas will dominate the industrial automation landscape in 2008. Australia is expected to “shine” while oil, gas and petrochemical, and offshore platforms are choice picks. For Yokogawa, its future lies with its flagship platform for the VigilantPlant initiative, the Centum VP. Billed as the next evolutionary step in the development of Centum series, its latest and 8th generation, goes beyond the

esigned to empower real-time decision makers at all levels of a plant’s operations, the Centum VP establishes a single real-time plant database that serves all functions in real time. It enables single-source seamless integration of advanced applications that manage plant information, stabilise processes, and improve operational efficiency. Yokogawa enhanced the functions of the Human Interface Station (HIS) for the VP. While maintaining full compatibility with the CS 3000, the new platform introduces a unified and intuitive operating environment. The HMI is designed to facilitate easy access to the right information. Another philosophy behind this HMI is the visualisation of operational know-how and consideration of information users’ mental models. This unified and intuitive HMI ensures that information users get prioritised, actionable information instead of a flooding of data. ENQUIRY NO. 0461

traditional production control system and offers a wholly unified operating environment for users. However, Yokogawa is not one to rest on its laurels. Already flushed with ideas on how to push the envelope further, developments on the next generation Centum series are currently being mapped. Backed by the R&D facility in Singapore and some 200 engineers dedicated towards the enhancement of the C e n t u m V P a rc h i t e c t u re , e v e n “ To k y o ( i t s h e a d o f f i c e ) h a s dedicated significant resources in the development of the new technology platform,” added Dr Lee. Mission Objective In a plug for the new baby onboard, D r L e e d e c l a re d : “ C e n t u m V P consolidates all decision making into one platform, giving our

customers the ability to make decisions with performance foresight and operational agility.” While Asia Pacific contributes about 25 percent of revenue to the company, the market shares of Europe and the US are also on the up. “Our organisation has grown by 500 percent over the last 10 years. In terms of growth, we will continue rising,” he enthused. “It is challenging, but we will continue to deliver value add solutions and continue to expand and achieve our growth targets to become the number one in industrial automation in the world by 2010.” In parting, he said: “We strive to be seen as a global company but in terms of customer services and quality – we pride ourselves as Asians, retaining the Asian characteristic: the vigilant attitude.” ENQUIRY NO. 0460 April 2008 | industrial automation asia  51


in business

T

he latest inca rnation of the Centum series of integrated production control systems by Yokogawa, Centum VP, which features a HMI that runs on both Windows XP and Vista, was introduced in early February at an event held in Singapore. President & CEO, Teruyoshi Minaki, provided the opening address. After an overview of the company’s Vigilant Plant concept by Mr Minaki, the new platform was finally unveiled. Kersi Aspar, executive VP, and Masatoshi Nakahara, VP, also gave engaging presentations on the challenges by the company and its goals, discussing the virtues of the new platform as well. The event incorporated a Q&A session where a panel comprising top level management from Yokogawa, fielded questions from the floor. One issue raised was whether the programme would be slowed down by Windows Vista. The panel replied: “The difference between Windows XP and Vista is usability. In terms of

graphics, Centum VP has an advantage in Vista.” Another asked if the screen was too small and suggested that it would be congested. To this the panel stated: “The VP’s HMI is flexible, and can display a maximum of five screens. We can also have a discussion with the customer and customise it according to his needs. As for alarms, they can be spotted easily as the screen blinks when a problem arises. It will then be possible to zoom in on the (blinking) screen.”

Moving Towards

One other question concerned the possible reaction of competitors to the launch of the new platform. “Currently, we have the leading market share in the Asia Pacific region. In Singapore alone, we have a 70 percent share and are continuing our R&D efforts in order to stay top,” answered the panel. “We are not worried about competition, only customers.” ENQUIRY NO. 2503

Yokogawa’s latest DCS, the Centum VP, aims for ‘operational excellence’ by enabling horizontal integration between plant operation units. By Derek Rodriguez

Complete Automation

The panel, from left to right: Mr Sng Hee Meng, Mr Masatoshi Nakahara, Mr Teruyoshi Minaki, Dr Tony Lee, Mr Kersi Aspar.

52  industrial automation asia | April 2008

ENQUIRY NO. 0000


in business

Common Pitfalls Of Outsourcing Despite the significant benefits that come with outsourcing, there are also risks and challenges for OEMs to consider. By Arena Solutions & Symphony Consulting

O

utsourcing has become a way of life for electronics manufacturers. Most original equipment manufacturers (OEMs) no longer consider manufacturing to be a core competency. Even in cases where some of this capability is retained in-house, there is an ongoing effort to evaluate more activities that can be offloaded to a contract manufacturer (CM). Despite the significant benefits there are also risks and challenges for OEMs to consider. Through our years of experience in working with electronics OEMs and CMs, we have observed seven common pitfalls that impact manufacturing outsourcing success. 1. Selecting The Wrong CM This is when an OEM selects a handful of contract manufacturers – or worse yet, a single CM – and starts discussing business without having a clear understanding of the appropriate selection criteria. 54  industrial automation asia | April 2008

Although cutting corners is often justified in a variety of ways, a major undertaking such as establishing your CM relationship must be based on a robust strategic foundation. Spend time to develop a clear set of selection criteria, understand your shor t-term and long-term requirements, and cast a wide net to evaluate multiple options. Validate your existing solution from time to time to ensure ongoing alignment with the direction of your business or product roadmap. 2. Quote-&-Go Approach The first formal exchange between an OEM and CM is typically the submission of a request for quotation ( R FQ). There are four potential problems with this quote-and-go approach: • Component Pricing Ambiguities The OEM and sometimes even

the CM do not clearly understand what assumptions are built into the pricing quotes. The best way to catch misquotes and inadvertent errors is to get the detail and look for discrepancies. • Lack Of Visibility Lack of price transparency is a lose/lose situation for both the CM and OEM, leading to a strained relationship between the two parties. • Supply Chain Model Unless you have had the early discussions upfront on what your supply chain model will look like, your CM quote can increase or decrease substantially. • Non-Price Issues Transportation, duties, tariffs, prototyping costs, engineering services, and RMA (return material


authorisation) services are among critical cost factors that are often overlooked. Finalising price should not be based on information flow from the CM to the OEM; it is a collaborative effort by both sides to put a mutually agreedupon framework of assumptions around the numbers. 3. Poor Contract Negotiation While most OEM-CM contracts are structured to offer adequate legal protection, we have found them to be generally light on important operational terms such as: • Inventory liability definition and reporting, particularly at the component level; • Supply/order flexibility and buffer programmes for demand upsides; • Price structure definition and adjustments; • Warranty coverage and ownership/

liability for epidemic failures; • Intellectual property ownership, especially with respect to manufacturing process improvements initiated by the CM; • Engineering change management, documentation, and transfer of product between CM facilities; • Delineation of responsibility for compliance with environmental regulations, in particular the European Union’s Restriction of Hazardous Substances (RoHS) directive; • Post-termination obligations, particularly in relation to inventory liability, continuity of supply, and records retention; • Reverse supply chain services and cost structure; • Delivery commitments and remedy provisions for delayed deliveries; • Cost structure for ser vices such a s d e s i g n , f u l f i l l m e n t , repair, prototyping, and test development.

Steve Woods, Colchester, Essex, UK

in business

OEM-CM contracts are generally light on some important operational terms.

Once you agree on the content of the term sheet, use that as the baseline to create a contract that defines these and other terms in further detail. The goal is to spend enough time upfront, with all the right parties, so there are no surprises when your CM receives the contract draft from you. 4. NPI Management New product introductions (NPI) are complex projects, incorporating numerous activ itie s a ssociated

Engineers Shape The Sustainable Future

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WEC is the amalgamation of 6 cutting edge conferences and 4 advanced training programmes running parallel with an international exhibition under one roof that is freely accessible by all delegates over two days Trainings

• 6th Annual Shutdowns & Turnarounds • Plant Reliability Management 2008 • Electrical Engineering and Maintenance Forum • Plant Start-up & Commissioning • Upstream Oil & Gas • 2nd Annual Property & Facilities Management

• Advanced Project Management for Engineers • HAZOP • Turbine Maintenance • Finance for Engineers

William Van Horne The ultimate platform for engineering and maintenance professionals with opportunities to benchmark, network and gain exposure to the latest engineering trends

Highlighted Conference of World Engineering Congress Plant Reliability Management 2008 The prime responsibility of managing reliability has often been given to the maintenance department or reliability engineers. However, focusing on only an equipment or mechanical perspective can lead to thinking in terms of hardware performance and can minimize the overall impact of reliability management. In Plant Reliability Management 2008, we will be connecting maintenance to two other primary functional components in a plant that influence reliability - operations and plant/equipment design. Creating a synergy between maintenance, operations and design will enable you to drive overall equipment effectiveness (OEE), cost management and ultimately, Return on Net Assets (RONA). Coupling this synergy with strategic business goals and decisions will enable you to achieve a unified approach to your company’s business and competitive performance. Join us to discover how Plant Reliability Management can be the unifying factor to customer, investor and staff satisfaction, and enable you to achieve a world-class plant performance.

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ENQUIRY NO. 769

Conferences

“NOTHING IS TOO SMALL TO KNOW, AND NOTHING IS TOO BIG TO ATTEMPT.”

April 2008 | industrial automation asia  55


in business with multiple components and subassemblies under a product’s bill of materials (BOM). In an outsourced environment, coordination of these activities gets even more complex, and we regularly hear about NPIrelated pitfalls such as the following:

• Lack Of CM Involvement This often occurs because the OEM doesn’t give visibility to the CM, leading to time-to-market delays. • Poor Communication The CM can’t seem to keep up with the numerous changes that occur, and may still be allocating resources to tasks that are no longer critical priorities. Build a process and infrastructure for rapid sharing of modifications made during the NPI process with your CMs and the suppliers affected downstream so that all levels of the supply chain are working together to incorporate changes. Also, implement a process with supporting systems that efficiently capture and process feedback from your CMs and part suppliers. 5. Change Management Processes The cha nge process ha s a high propensity for error due to the large number of people involved and in some cases, due to the technical complex ity a ssociated with the change. To manage this process more effectively: • Ensure that the complete product record is available to all involved in change implementation. • Define and document a robust set of ‘change management’ rules based on best practices such as form-fit-andfunction-based revision change. 56  industrial automation asia | April 2008

Philip MacKenzie, London, UK

• Manufacturing Data Inaccurate BOM lead to assumptions by the OEM about how and when certain tasks will be completed by the CM, while the CM may be finding their own solutions to work around the missing information.

OEM relies on its manufacturing partners to perform a range of activities, from procurement, inspection, and fabrication, to assembly, quality assurance, shipment, and sometimes even service.

• Before implementing changes, involve your CMs and obtain their feedback on the change and its impact, as well as potential avenues to reduce any negative impact. • Set up the change process to involve multiple tiers of the supply chain in the change, even beyond the CM. • Build a change ‘audit trail,’ detailing exactly what change was approved, on what date, by whom, and what the disposition actions were per inventory location. 6. Environmental Compliance Management In an outsourced manufacturing environment, an OEM relies on its manufacturing partners to perform a range of activities, from procurement, inspection, a nd fabr ication, to assembly, quality assurance, shipment, and sometimes even service. Several of these activities are part of the ‘compliance controls’ that are necessary to minimise compliance risk. The following are common mistakes that lead to a broken compliance process, and with that, an increased compliance risk: • OEMs treat compliance as an isolated responsibility often delegated to someone in engineering, rather than as a series of controls across the entire design

and manufacturing process; • Compliance is managed as a ‘flag on a part number’ rather than integrated into the configuration management processes. • The OEM doesn’t have one central, complete and accurate product record, and hasn’t completely verified sourcing for all parts and materials in the full BOM. • Many OEMs are using manual systems like spreadsheets and file servers simply because those are the tools they have always used. 7. Ignoring Hidden Costs E xe c u te d co r r e c t l y, o f f sh o r e manufacturing works best if you have done your homework and have robust business controls in place to manage it. Before you make any decisions about transferring to or launching production in China or elsewhere in the region, travel there and visit some suppliers that you have identified through trusted contacts. It is essential to put in place the appropriate tools to collaborate effectively across time and language barriers, and the disciplined processes to ensure that hand-offs and changes are clearly communicated. This will become essential in the NPI phase, and, once a product is in production, for managing the myriad of changes that are inevitable in fast-moving environments. ENQUIRY NO. 2504


in business

Market Report:

Robust Growth For Process Industry Automation The worldwide market for process automation systems is expected to grow at a compounded annual growth rate of 9.6 percent over the next five years. By Himanshu Shah, senior analyst, Arc Advisory Group

2011

2010

2009

2008

2007

50,000.0

2006

P

rocess industry automation continues to experience solid worldwide growth as plants must continue to improve performance. End users facing globalisation are driving plant performance at a level that would be inconceivable without modern process automation systems and business processes. As a result, automation systems for process industries will experience healthy growth. The worldwide market for process automation systems is expected to grow at a compounded annual growth rate (CAGR) of 9.6 percent over the next five years. The market was nearly US$30 billion in 2006 and is forecasted to grow to over US$47 billion in 2011. Process automation technologies help to achieve industry business objectives for improved plant utilisation, yields, product quality, availability, safety, flexibility, and delivery performance. Constant cost pressure in process industries leaves no alternative but to improve plant performance, and process automation technologies play a key role in achieving this. nalyst Himanshu Globalisation Drives Growth Many trends are emerging as a result of globalisation, which means more markets, more products, and more partners. Opportunities expand, but so do the challenges for global manufacturers.

Automation Systems For Process Industries Worldwide Outlook (US$Millions) Companies are selling their products around the world and they are facing competition from a growing number of global players. One reason the automation systems business will do so well over the next few years is the huge list of challenges and changing conditions in the global business environment that manufacturers must respond to. These challenges include globalisation, the need to act quickly and with agility to emerging market opportunities, dealing with a shrinking base of educated and well trained personnel, and increasing pressure to improve financial performance. These challenges are driving a significant change in the way that end users approach everything they use

to control production, engineering, operations, and maintenance across the manufacturing enterprise. Automation is a ticket to be a participant in this flat world, and therefore, process automation products are expected to have robust growth as they are used across industrial segments, ranging from Food & Beverage and Metals & Mining to Chemical and Water & Waste industries. Regional Scenarios S evera l fac tors, f rom c ap acit y ut ilisat ion to product iv it y a nd industrial production shape the growth of the global automation marketplace and will affect the market in the coming years. Despite troubles in the US and Canadian economies, the global outlook for automation and manufacturing remains bright. Higher energy prices continue to contribute to increased capital investments and large project backlogs for oil, gas and refining companies. The pharmaceutical and biotech industries remain strong, and growth in Asia and other developing regions remain high. Asia remains the centre of growth, but the Middle East, Eastern Europe, and Latin America continue to show strong growth as well. ENQUIRY NO. 2505

April 2008 | industrial automation asia  57


design focus

Use f Waste Waste-to-resources is an approach that involves the control of environmental pollution, waste minimisation and the consideration of waste products as potential resources before disposal. By Augustine Quek

n recent years, a world consensus has been reached on the need for sustainable development. According to the United Nations Environment Programme’s Global Environment Outlook 4 (GEO-4), since 1987, global populations has risen 34 percent, with more than 50 percent of the world’s population living in cities currently. The report also found that the world’s population has reached a stage where the amount of resources needed to sustain it exceeds what is available, with the average person’s footprint being 21.9 hectares per person, while the Earth’s biological 58  industrial automation asia | April 2008

capacity is only 15.7 hectares per person. An industry has since developed in the recovery and reuse of waste outputs from one process, as inputs in another process. Wastes from industrial processes can be recycled according to its characteristics, as inorganic materials, organic and plastics. Recovering Inorganic Waste Inorganic waste includes all manner of metals and minerals, from solid forms like concrete from construction wa ste s, to meta ls dissolve d in wastewaters from electroplating a nd ele ct ronic indu st r ie s. T he

Jesuino Souza, AssaÌ, Brazil

Making

technologies to recover inorganic wastes are quite mature as these wa ste s have traditiona lly been recycled and reuse. This is because metals can be recycled indefinitely without a loss in its quality, while the economics of reusing minerals are favourable. Rapidly dwindling reserves and rising commodity prices in recent years have encouraged the use of these technologies. An example of engineering sophistication is the power plant. Although it is a cornerstone of modern civilisation, the solid waste it produces has conventionally occupied valuable landfill space. Only recently has the waste products, such as calcium sulfite (gypsum) and ash, begun to find new uses. Calcium sulfite, also known as gypsum, is produced when lime is used to react with sulfur pollutants in


design focus National Gypsum’s production of drywalls for 70,000 homes. Universal Aggregates, of Bridgeville Pennsylvania, converts more than 400 tonnes of coal combustion by-products (CCB) produced by Birchwood Power Facility into valuable building material. The aggregate products are typically used to produce lightweight masonry blocks and concrete or asphalt paving material, and meet the quality and industry standards for building. It is also claimed that the Birchwood manufacturing plant is able to produce 167,000 tonnes of aggregate at full capacity annually. Easily Biodegradable Organics There is wide variety of organic wastes being reused or recycled, such as animal excreta, fruit stalks and husks from agriculture, sludge from wastewater, or food wastes. For organic wastes that are easily biodegradable, like food wastes and organic sludges, there are two

main methods of biodegradation: aerobic, ie: with the aid of oxygen, or anaerobic, in the absence of oxygen. Composting has been used throughout the world as a useful way of reclaiming nutrients from organic refuse, producing fertilisers or soil conditioners for farms, parks and gardens. This also saves valuable landfill space and possible contamination of land and water due to landfill leachates. Biogas is produced by means of anaerobic digestion. Anaerobic digestion yields

Recycling of waste plastics involves reprocessing the material into useful products, sometimes completely different from their original state.

Ivan Philipov, Plovdiv, Bulgaria

scrubber systems designed to reduce sulfur oxide (SO x) emissions from power plants burning sulfur-containing fuel. Gypsum has traditionally been mined for many uses, such as in cement, as a fertiliser, and plaster making, with significant environmental damage. In order to use gypsum produced from power plants, several methods have been engineered. One method is known as called Forced Oxidation Gypsum, developed by First Energy, with an operating system at the Bruce Mansfield power plant in Shippingport, Pennsylvania, USA. The patented process transforms t h e s c r u b b e r b y p ro d u c t i n t o commercial grade gypsum by injecting oxygen. A wall board producing company (National Gypsum Co) took advantage of this by building an US$85 million drywall facility across the street from the Mansfield plant. A conveyor belt transports the half a million tons of gypsum from the utility to the drywall facility, facilitating

Engineers Shape The Sustainable Future

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William Van Horne The ultimate platform for engineering and maintenance professionals with opportunities to benchmark, network and gain exposure to the latest engineering trends

Highlighted Conference of World Engineering Congress 6th Annual Plant Shutdowns & Turnarounds Planning and managing shutdowns, turnarounds and outages in the process and manufacturing plant environment is a complex and demanding function. If turnarounds are not properly planned, managed and controlled, companies run the risks of serious budget overruns, costly schedule delays and negative impacts on customers. As the plant shutdown is the major component of plant downtime and maintenance costs, proper plant turnaround management will have a significant impact on the bottom line. In that bottom line, many plant operators are still looking into ways of reducing costs via improved and successful shutdown & turnaround planning processes. Attend this highly focused conference and transform strategies to become more effective. See your returns in the form of improved returns from using the right strategies in gaining excellent world-class plant shutdown and turnaround. Do not miss out 6th Annual Plant Shutdowns & Turnarounds in Bangkok and ultimately become the leader in your industry.

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ENQUIRY NO. 770

Conferences

“NOTHING IS TOO SMALL TO KNOW, AND NOTHING IS TOO BIG TO ATTEMPT.”

April 2008 | www.iaasiaonline.com  59


design focus

David Butler, Mobberley, Cheshire, UK

methane that can be used as a fuel, thus facilitating renewable energy generation. The residual nutrient rich liquor and digestate is suitable for use as fertiliser. Biogas can be produced by digesting human, animal or vegetable waste in specially designed digesters. Animal waste is particularly suitable for biogas production because it is often available is large quantities and also has a suitable carbon to nitrogen ratio (C:N ratio). Some countries have initiated largescale biogas programmes, Sri Lanka being an example. A project being implemented by the Colombo Municipal Council uses organic waste from local city vegetable markets to produce biogas and compost. The digesters, developed by the National Energy Research and Development Centre, are 20 foot diameter floating dome digesters each with a capacity of 40 tonnes dry waste. The waste produces approximately one cubic metre of biogas per tonne per day, equivalent to 7500 kilowatt hours of electricity each year. The system also yields 300 tonnes of saleable fertiliser each year. A amazing case of recycling organic waste is an eco-farming project in Fiji. The Montfort boys’ school there has linked five different micro- industries so that the waste from each becomes 60  industrial automation asia | April 2008

Willi Heidelbach, Germany

There is wide variety of organic wastes being reused or recycled, such as animal excreta, fruit stalks and husks from agriculture, sludge from wastewater, or food wastes.

Metals can be recycled indefinitely without a loss in quality.

a key input to another. Starting with the barley mash being discarded by a large Fijian brewery, a variety of products would result: crops of fresh mushrooms, chickens, fish, vegetables, and fuel for electric power. The brewery sludge is used as a feed for growing mushrooms, which in turn produces a residue for feeding chickens and pigs. The animals’ wastes are then anaerobically digested to produce methane to power the school building, as well as a residue. The residue is then aerobically treated by flowing through shallow cleansing ponds, where algae is produced. This is dropped into a large fish pond as fish food. Flowers, strawberries, and high-value vegetables such as golden needle are grown in the pond so that their roots can draw nutrients from the dissolved fish waste. This has not only supplied food to Fijians, but has also avoided some 400,000 cubic metres per year of brewery’s waste from polluting t h e s e a a n d d e s t ro y i n g l o c a l marine life. Conversion Of Organic Waste Non - biologica l methods such a s enha nced dr y ing or through thermochemical modification are recent innovations. For example, Ke pp e l S e g he r s slu d g e d r y i n g

a n d b r i q u e t t i n g t e c h n o l o g y, called Hardpelletiser, is capable of producing dr y pellets from a variety of sludge wastes, including municipal sludge and industrial sludge of varying types and origins (primary and secondary, raw and digested etc). The process grows the biosolids gently layer by layer, similar to pearl formation in an oyster. The Hardpelletising process, with water evaporation, is strictly indirect and no oxygen is allowed into the system. The process ensures the stability and pasteurisation of the pellets. Keppel claims Hardpellets are of high hygienic quality and are easily handled, transported and stored for long periods of time. The Hardpellets can be used for many applications, ranging from soil improver and fertiliser to green fuel, depending on the sludge characteristics and the local environmental legislation. Thermochemical conversion (TCC) involves using heat to break down long-chain carbon molecules into its constituents, also termed thermal depolymerisation. Such processes now include other reactions such heating with water. Several commercial TCC processes are in operations. EnerTech operates the ‘SlurryCarb’ process, which uses


design focus similar technology to decarboxylate wet solid biowaste, which can then be physically dewatered and used as a solid fuel called E-Fuel. The plant at Rialto is said to be able to process 683 tonnes of waste per day. The Hydro Thermal Upgrading (HTU) process, originally developed by Shell, is now operated by Biofuel BV. It uses superheated water to produce oil from a range of biomass and domestic waste. A demonstration plant is due to start up in The Netherlands said to be capable of processing 64 tonnes of biomass (dry basis) per day into oil. Thermal depolymerisation differs in that it contains a hydrous process followed by an anhydrous cracking/ distillation process, although upgrading of the raw HTU product is also possible. Plastic Recycling Plastic wastes are increasing in ubiquity and is different from organic wastes in that it is usually dr y. Recycling of waste plastics involves reprocessing the material into useful products, sometimes completely different from their original state. Recently, Hewlett-Packard (HP) has developed a closed loop plastic recycling system that can upcycle post-consumer recycled plastics, such as water bottles and ink cartridges, in the production of new original HP inkjet print cartridges. The company’s recycling process facilitates the combination of multiple sources and grades of recycled plastics. The process has resulted in HP inkjet cartridges with 70 to 100 percent recycled content that still meet HP’s performance standards. Plastics and metals recovered from products recycled by HP have been used to make a range of new products, including auto body parts, clothes hangers, plastic toys, fence posts, serving trays and roof tiles. Industrial Symbiosis I n t h e co n te x t o f s u s t a i n a b l e engineering, the term can be applied to industrial co-operation between different plants, where one company may use the waste produced by

another as a resource. The essence of industrial symbiosis is can be illustrated in another concept termed by-product synergy (BPS). BPS emerged in the early 1990’s when Chaparral Steel and Texas Industries Inc (TXI) integrated their steel and cement making processes. Slag from TXI’s steel-making process was used to make high-quality Portland cement. The resulting cement process produced about 10 percent more cement, while using less energy and creating less nitrogen oxide emissions. This led to the BPS practice, which is a facilitated information exchange among engineering and operations staff of participating companies. These companies, from different industry sectors share information on their feedstock needs as well as unwanted by-products. Through extensive collaboration and a systemic analysis of feedstocks and waste streams, the participants identify potential synergies. A classic case, often quoted by industrial ecologists is the story of the spontaneous but slow evolution of the ‘industrial symbiosis’ at Kalundborg, Denmark. The industrial symbiosis of Kalundborg is built as a network co-operation between six large processing companies, one

waste handling company and the Municipality of Kalundborg, including: Energy E2 Asnæs Power Station, the plasterboard factory BPB Gyproc, the pharmaceutical plant Novo Nordisk, the enzyme producer Novozyme, the oil refinery Statoil, Bioteknisk Jordrens Soilrem as well as the waste company Noveren and Kalundborg Municipality, exploit each other’s residual or byproducts on a commercial basis. For example, Asnæs power station supplies steam to both Statoil and Novo Nordisk for heating of their processes, essentially functioning in a co-generation mode. Excess gas from the operations at the Statoil refinery is treated to remove sulfur, which is sold as a raw material for the manufacture of sulfuric acid, and the clean gas is then supplied to Asnæs power station and to Gyproc as an energy source. Asnæs power station also produces gypsum in its desulfurisation unit, which is then used in the manufacture of plasterboard at Gyproc. Novo Nordisk’s large quantity of used biomass from its synthetic processes is used as a fertiliser by the local farming communities. Finally, residual heat is also provided by Asnæs power station to the district heating system of the town, via heat exchangers. ENQUIRY NO. 2506

Industrial Park of Kalundborg, Denmark Bitor Inc

Gyproc plasterboard

soil conditioner

Aalbrog cement factory

ash gypsum

gas

Statoil refinery

gas

steam

ash

Asnæs Power Station

waste heat (return)

Municipality of Kalundborg

sulfur waste heat

sulfuric acid producer

Novo Nordisk fish farm

yeast

sludge

pig farm

spent biomass

local farms

April 2008 | www.iaasiaonline.com  61


products & Services Adlink: Distributed PAC W it h Ad l i n k ’s D PAC - 3 0 0 0 se r ie s of d i st r ibute d programmable automation controllers, all the functional blocks, such as digital inputs/ outputs, AD/DA device, relay switch control, thermocouple inputs, and motion controller can be connected together and communicate with a HSL fieldbus via Ethernet cables. They can be distributed near the sensors, actuators, or servo motors. The DPAC-3000 not only offers two USB 2.0 ports but also dual LAN. The DPAC-1000 features four COM port designs and offers one fixed RS-232 and 3 selectable RS-232/RS-422/RS-485 with auto data flow control. With multiple COM ports, any COM port device and RS-485 data acquisition module can be connected. The DPAC can tolerate up to 100 G shock and up to 5 G vibration. It has a fanless design to increase MTBF and reliability, and includes thermal heat sink dissipation calculation and simulation to ensure operational stability.

Contec: Display Graphics Distribution System

Contec’s FlexNetViewer is an IEEE802.3u-compliant display graphics distribution system. The transmitter, RP-VL-S-01, converts the VGA input image signals into LAN packet signals before transmitting them. The receiver, RP-VL-R-01, converts received LAN packets into VGA image signals in order to transfer them to the monitor. When using both transmitter and receiver, monitors can be connected in a 1:1 or 1:N configuration without depending on the application’s hardware or OS. It has serial I/O (RS-232C) and digital I/O (4channels non-isolated LVTTL level input and 4channels non-isolated LVTTL level output). Application utilities provide a variety of connectivity options, allowing the PC to be used as a transmitter or receiver.

Enquiry no. 2603

Enquiry no. 2601

Advantech: Communication Controller

Euresys: Frame Grabber

Advantech Corp’s Adam-6501 communication controller has a 400 MHz Intel XScale processor packed into it and is equipped with a CompactFlash slot. There is also an embedded web server, FTP server, and telnet ser ver that make it possible to create a remotely operated controller. For the operating system, the ADAM-6501 has embedded Microsoft Windows CE NET 4.2, and for applications there is 32 MB of onboard flash memory and 64 MB SDRAM. It has an option to bundle with Advantech Studio, Advantech’s web-enabled HMI/ SCADA software. Networking is taken care of with one RS-232, one RS-485 and one RJ-45 10/100BaseT Ethernet port. Drivers for Modbus/RTU and Modbus/TCP ensure networking integration goes smoothly.

The Domino Symphony boards by Euresys are frame grabbers that are equipped with 10-bit A/D converters clocked at up to 65 MHz and an on-board 64 MB memory. Offering an interface to four single-tap monochrome analogue cameras, the boards benefit from D³ Technology. They expose multiple general purpose I/O lines available in parallel on a standard HD-26 bracket connector and on an on-board header. The frame grabbers are available in two form factors. The Domino Symphony is a conventional PCI board equipped with a 64-bit, 66 MHz bus and the Domino Symphony PCIe is a 1-lane PCI Express board. Furthermore, a MultiCam interface is provided to operate the frame grabber on various Windows and Linux operating systems.

Enquiry no. 2602 62  industrial automation asia | April 2008

Enquiry no. 2604


products & Services

Fluke: Thermal Imagers

Ifm: Vibration Monitor

Fluke Corporation’s Ti10 and Ti25 thermal imagers incorporate IR Fusion, a technology that integrates infrared and visual images in full screen or picturein-picture views for enhanced problem detection and analysis. The imagers are tested to withstand a drop of 6.5 feet and are IP54 rated to withstand water and dust. They have a widescreen full colour LCD and a temperature measurement range of –20°C to 350°C for the Ti25 and –20°C to 250°C for the Ti10. Fluke SmartView software is included and the imagers come with a 2 GB SD memory card (and card reader), a rechargeable internal battery and AC power supply/ battery charger.

The compact diagnosis system efector octavis eva luate s v ibration signals using the methods of frequency a na lysis. T he system uses a micromechanical acceleration sensor. The efector octavis is designed for the early detection of rolling element bearing damage or unbalance. The unit type VB1001 monitors up to t wo different objects. The unit type VE1001 can monitor up to five different objects or 20 individual frequencies. (An object is defined as a rolling element bearing or a shaft.) First the acoustic emission is detected, then the frequency spectrum is calculated and the rolling element bearing state or the unbalance etc is evaluated. The condition can be directly read on site and is signalled by binary switching outputs. The switching signal can be transmitted via unscreened cables. Connection to bus systems is also possible.

Enquiry no. 2605

Huba Control: Differential Pressure Module The relative and differential pressure modules type 698 are suitable for monitoring pressure and flow in air conditioning systems and in the laboratory sector. The modules a re selectively ava ilable with two limit switches which are adjustable with a potentiometer, three digit LED display, square root extraction and standardised output signals. The built in pressure transmitters are types 516, 402 or 663, depending on the pressure range. They feature a response time of less than 20 ms and a load cycle of 20H ey also have a protection standard of IP65. The modules have a rugged measured value detector, combining diaphragm technology with a ceramic element, and a high overpressure safety margin. Enquiry no. 2606

Enquiry no. 2607

Igus: Energy Chain Universal Module Igus GmbH’s universa l module ‘Triflex RS’ guides the ‘Triflex R’, the multidimensional energy chain system with complete freedom of movement in the X-, Y- and Z-a xes, close to the robot arm, and avoids any looping. It can be mounted directly to standard fastening holes of most robots. The ‘Triflex R’ is a product family for robot users and manufacturers and the range comprises more than 100 components already. This modular approach means that applications from large-scale welding robots to small handling robots can be realised. Project planning is not necessary: the required freemoving length of energy chain is added to the front area of the robot and fastened to the sixth axis by means of a mounting bracket. Enquiry no. 2608 April 2008 | industrial automation asia  63


products & Services

Jetter: Mask Editor

NXP: MOSFET

Jetter AG’s ISO-Designer is a mask editor for ISOBUScompliant terminals in the mobile automation sector. ISO 11783 is a global standard for networking agricultural vehicles. The ISO-Designer serves to create and modify ISO 11783-compliant IOP files for Virtual Terminals (VTs). In addition, the VTs can be simulated on the PC with the ISO-Designer. JetViewSoft masks can be implemented for various target platforms - with HTML masks for web browsers, for Windows-CE devices, for customised runtime software and now also for ISO-compliant operating terminals or corresponding end devices.

Measuring 1.0 x 0.6 mm with a 0.5 mm profile, NXP’s SOT883 MOSF ETs deliver power dissipation and performance comparable to the SOT23. NXP has eliminated the leads, which both frees up additional board space and improves thermal performance. This combined with Rds(on) values of less than 0.65 ohms at 2.5 V allows the MOSFETs to offer higher current carry capacity than currently available 1.0 x 0.6 mm MOSFETs. The series also features turn on times between 12-16 ns and turn-off times between 17-24 ns. Manufactured using pure tin plating, high-efficiency packing techniques and green plastics that dispense with toxic flame retardants, the SOT883 MOSFET devices meet all environmental protection targets. The high packing density also fits 10,000 devices on a standard 180 mm reel, thus lowering assembly costs and inventory requirements.

Enquiry no. 2609

Enquiry no. 2611

LMI: Line Sensor

Omron: Inverters

L M I Te c h n o l o g i e s’ EyeCon 20 0 0 la ser line sensor is not only designed for high frequency and accuracy measurement of mat su r fa ce s a n d sh i n y black materials, such as rubber, but also for measuring thickness and width and profiling component preparation stock material. It provides a profile rate of 4,000 samples per second. The sensor also provides a line laser profile rate of 2 kHz for lower speed applications. The standard design features of the sensor provide binocular vision inspection. The sensor also features a direct encoder input to control global synchronisation better than +/- 1.0 microsecond using a Gigabit Ethernet protocol. The total integration architecture of the EyeCon 2000 uses four sensors and an encoder signal. Power over Ethernet allows mounting the sensor at a distance up to 100 metres away from the controller.

The number overall steps required t o u s e O m r o n’s 3G3JX, 3G3MX and 3G3RX series inverters have been reduced, starting w it h w i r i n g a nd parameter settings and extending to the operation and maintenance. The 3G3JX and 3G3MX are able to be mounted sideby-side closely together. Vector Control Mode is set in 3G3MX and 3G3RX as a factory default to provide higher starting torque than V/F control. Parameters can also be set for a high starting torque of 200 percent at 1 Hz. The 3G3RX’s functions include position command, speed commands and acceleration and deceleration times which can be set in parameters to perform up to 8 steps positioning. The teaching function can also be used to store positioning points in memory by actually moving the machines. All models also conform to international standards such as CE, UL/cUL and RoHS.

Enquiry no. 2610 64  industrial automation asia | April 2008

Enquiry no. 2612


products & Services products & Services

Raytek: Infrared Linescanner

Tibbo: Wi-Fi Add-on Board

R a y te k ’s M P15 0 h i g h speed infrared linescanner prov ides a noncontact temperature measurement solut ion de sig ne d for modern manufacturing processes. One key feature is a scan speed up to 150 Hz. Another feature of the MP150 is the on-board Ethernet TCPI/IP communication capability. Using existing industrial Ethernet infrastructure, the linescanner can be assigned a unique IP address and accessed from any computer on the network. To speed-up alignment, each unit has an internal line laser which indicates the exact line-of-sight of the linescanner. This laser, fully protected by its housing, projects a clearly visible laser line on the target even while it is collecting data at full speed A complete suite of software solutions is available for the MP150. The system packages allow the user to configure the system to analyse thermal data to monitor and control their manufacturing processes. The MP150 utilises the same form-factor and mechanical components as previous models and is completely reverse compatible.

The WA1000 is a Wi-Fi add-on board for the EM1000 Basic-programmable embedded module and implements a 802.11b interface. The 37.0 x 25.0 mm board piggy-backs on top of the EM1000 and communicates with the latter via a high-speed SPI interface. The board features an integrated chip antenna. Additional external antenna can also be connected for better range. It is fully supported in the Tibbo BASIC programming environment via a Wi-Fi object available on the EM1000W platform. a a Wi-Fi object available on the EM1000W platform.

Enquiry no. 2613

Enquiry no. 2615

Sunx: Laser Marker

Westermo: Ethernet Extender

Sunx’s LP-V series 12 Watt FAYb laser marker is capable of a 700 cps output. Equipped with a high speed galvanometer that reduces tact time, it also has a 20 kW peak power. Marking depth can be kept to 10μm or less. The laser marker allows colouring on resins and its focus adjustment control allows fine tuning without moving the marking head or target. Additionally, it is completely air cooled and has machine readable barcode and 2D code marking. It comes equipped with an encoder interface to mark moving objects, eg: objects on an assembly line. Other standard features of the LP-V series includes a code function (Data Matrix, various bar codes, etc) and standard functions such as counters, expiry date and lot number generation.

The Westermo DDW-220 is an Ethernet extender with a built-in four port Ethernet switch. It can support transfer rates up to 5.7 Mbits/s and an operating distance of up to 10 km at lower data rates. The DDW-220 uses a transient blocking unit on each DSL line to provide both overcurrent and over-voltage protection on the line. The the unit allows for the surrounding air temperature to be between –40 to 70°C. To allow for uninterrupted communication the units are supplied with redundant power inputs that can be powered from two separate supplies and handle an operating voltage range of 16 – 60 VDC.

Enquiry no. 2614

Enquiry no. 2616 April 2008 | industrial automation asia  65


eVENT REVIEW

World Press Day

2008

Design technology is vital to helping Asian companies innovate faster and more efficiently in order to gain a competitive advantage. By Derek Rodriguez

R

uthless commoditisation means designers of all kinds must differentiate themselves with great ideas to better compete in the global economy,” said Autodesk APAC senior VP Patrick Williams at its inaugural SEA World Press Day which was held in St Regis Hotel, Singapore on February 29. At the event attended by journalists from around the region, global trends that have an impact on the business of design were underlined. The advent of digital lifestyles has led to an increased adoption of internet and mobile technology. Furthermore, the effect of globalisation means that global companies are setting up design centres in the region. Infrastructure boom was another point raised; new projects are expected to grow by 45 percent in 2008. Climate change is a consideration as well, with green design becoming more and more of a key driver. “It’s no longer enough to focus solely on aesthetics,” Mr Williams forewarned, referring to how design technology is used to create models and interconnected workflow to observe how an idea looks and performs. Asean regional director Denis Branthonne pointed out: “Companies

have to find a way of being productive, and for many, the key is moving from 2D to 3D.” Digital models, rather than physical prototypes, serve a more valuable function by representing a project in all its complexity. “With digital prototyping, you are able to analyse, simulate, and optimise the design,” added senior sales manager Vincent Chia. Designing Sustainability Design knowledge is a crucial issue for governments and educators in Asia who want to move their economies towards important development goals like design innovation, sustainable development, and grooming capable talent. Business development manager Ho Chow Jin described the company’s definition of sustainability as “Meeting the needs of the present while improving the ability of future generations to meet their own needs.” For Autodesk, their business strategy in SEA consists of fine tuning reseller networks to boost channel capabilities (by focusing on solution delivery), partnering governments and companies to support green design initiatives, supporting local firms to compete globally, and investing in education initiatives (up to 8 – 10 percent). Educating The Future Education programmes director Tom Joseph revealed Autodesk’s education strategy of concentrating on emerging markets and cultivating design awareness at an early age. He explained: “Eighty-four percent of the world’s population is within emerging markets. This tells us the workforce of the future is coming from emerging countries.” A highlight of the event was Naveen Bhat’s impressive building information modelling (BIM) demonstration. His flawless navigation of the application’s maze of functions evoked a positive response from the audience and prompted Ray Pur vis of Hyder Consulting request for his CV, tongue in cheek of course.

Mr Chia dicussing digital prototyping and its uses. 66  industrial automation asia | April 2008

Mr Bhat providing a compelling BIM demonstration.

ENQUIRY NO. 2701


CalendarOf Events2008 APRIL 1 – 3 AsiaWater 2008, Malaysia

Kuala Lumpur, Malaysia AMB Exhibitions Sdn Bhd Email: support@ambexpo.com Web: www.asiawater.org

7 – 10 Yokogawa Annual Technology Fair & User Conference

Hilton Americas Houston, Texas, USA Yokogawa Corp of America Email: kari.mitchell@us.yokogawa.com Web: www.yokogawa.com/us

9 – 11 RFID World Asia 2008

Suntec, Singapore Terrapinn Pte Ltd Email: wendy.tay@terrapinn.com Web: www.terrapinn.com/2008/rfid

13 – 16 Citect 7th Global Partner Conference Collaborate 2008

Corinthia Grand Hotel Royal Budapest, Hungary Citect Email: partnernews@citect.com Web: www.citect.com

21 – 25 Hannover Messe 2008

Hannover Fair Grounds, Germany Singaporean-German Chamber Of Industry And Commerce Email: info@hf-singapore.com Web: www.hannovermesse.de

22 – 24 China EPower ‘08

Intex, Shanghai MP Asia Pte Ltd Email: pearlyang@mpinetwork.com Web: www.china-epower.com

MAY

7 – 11 Metaltech 2008, Malaysia

Putra World Trade Center Kuala Lumpur, Malaysia Trade-Link Exhibition Services Email: info@tradelink.com.my Web: www.tradelink.com.my/metaltech/

26 – 29 Aseanplas 2008

Singapore Expo Messe Düsseldorf Asia Pte Ltd Email: aseanplas@mda.com.sg Web: www.aseanplas-singapore.com

JUNE 5 – 8 Manufacturing Hanoi 2008 Hanoi, Vietnam Chan Chao Int’l Co Ltd Email: mis@chanchao.com.tw Web: www.chanchao.com.tw

10 – 13 ICA 2008

Kuala Lumpur, Malaysia Facon Exhibitions Sdn Bhd Email: sales@faconex.com Web: www.faconex.com

11 – 14 Propak Asia 2008, Thailand

Bangkok, Thailand Bangkok Exhibition Services Ltd Email: propak@besallworld.com Web: www.besallworld.com

18 – 19 World Engineering Congress

BITEC, Bangkok, Thailand Reed Tradex Email: channipar@reedtradex.co.th Web: www.assemblytechexpo.com

19 – 22 Assembly Technology 2008

Bangkok Thailand Marcus Evans (M) Sdn Bhd Email: kellyl@marcusevanskl.com Web: www.marcusevanskl.com

1 – 5 Robot Taiwan 2008

Taipei WTC Exhibition Hall Taiwan External Trade Development Council Email: robot@taitra.org.tw Web: www.robotaiwan.com

5 – 7 Semicon Singapore 2008

Suntec, Singapore Semi Singapore Pte Ltd Email: ccchan@semi.org Web: www.semiconsingapore.semi.org

JULY 9 – 12 MTA Vietnam 2008

Giang Vo Exhibition Centre (VEFAC) Hanoi, Vietnam Singapore Exhibition Services Email: events@sesallworld.com Web: www.mtavietnam.com

SEPTEMBER 9 – 12 Globaltronics 2008

Suntec, Singapore Reed Exhibitions Email: melanie.mostafa@reedexpo.com.sg Web: www.globaltronics.com.sg

17 – 19 Industrial Automation Vietnam

International Exhibition & Convention Centre (HIECC) Ho Chi Minh City, Vietnam Hongkong Exhibition Services Ltd Email: exhibit@hkesallworld.com Web: www.iavietnam.com

25 – 28 Automation 2008

Bombay Exhibition Center, India IED Communications Ltd Email: ied@vsnl.com Web: www.automation2008.com

OCTOBER 13 – 16 SCM Logistics World 2008

Raffles City Convention Center, Singapore Terrapinn Pte Ltd Email: stella.teo@terrapinn.com Web: www.terrapinn.com/2008/scmlog

22 – 24 ProcessCEM Asia 2008

Suntec, Singapore Association of Process Industry (ASPRI) Email: processcem2008@aspri.com.sg Web: www.processcemasia.com

NOVEMBER 20 – 23 Metalex 2008, Thailand

BITEC, Bangkok, Thailand Reed Tradex Email: metalex@reedtradex.co.th Web: www.metalex.co.th

DECEMBER 2 – 5 OSEA2008

Suntec, Singapore Singapore Email: es@sesallworld.com Web: www.osea-asia.com

Aprilindustrial 2008 | www.iaasiaonline.com  automation asia  67 67


ADVERTISING Advertising Index

64

ADVERTISER

PAGE NO

ENQ NO

Advantech Co Singapore Pte Ltd

13

760

Amphenol

23

777

Asean CC Link PROMOTION CENTRE

1

648

Bangkok Exhibition Services Ltd

45

763

Bosch Rexroth Pte Ltd

25

764

CEJN Products Far East Pte Ltd

41

779

Citect Pte Ltd

5

768

Daifuku Mechatronics (Singapore) Pte Ltd

29

773

DHL

3

765

Exxon Mobil Asia Pacific

17

647

Facon Exhibitions Sdn Bhd

39

757

Fluke South East Asia Pte Ltd

14

751

|

IndustrialAutomationAsia

I N D E X

ADVERTISING SALES OFFICES HEAD OFFICE SINGAPORE Eastern TRADE MEDIA PTE LTD 1100 Lower Delta Road #04-02 EPL Building Singapore 169206 Tel: 65-6379 2888 Fax: 65-6379 2805/6379 2806 SINGAPORE: Caroline Yee carolyee@epl.com.sg

Fuji Electric FA Singapore Pte Ltd IBC

758

Hitachi Asia Ltd

10

737

Hong Kong Exhibition Services Ltd

49

746

ICPDAS Co Ltd

33

775

IED Communications Ltd

53

732

ifm Electronic Pte Ltd

9

766

Igus Singapore Pte Ltd

14/19

771/772

7

756

55/59

769/770

Mitsubishi Electric Asia Pte Ltd

21

718

N-Tron

15

762

Omron Asia Pacific Pte Ltd

27

774

Panasonic Electric Works Asia Pacific Pte Ltd

37

759

PIAB Asia Pacific Pte Ltd

19

778

Rockwell Automation Southeast Asia Pte Ltd IFC

776

Siemens Pte Ltd - Automation and Drives OBC

747

Trade-Link Exhibition Services Sdn Bhd

35

755

Turck Singapore Pte Ltd

11

761

FOUR WEEKS before the date of publication.

Yamatake Controls Singapore Pte Ltd

12

767

Please contact our nearest advertising office for more details.

Invensys Process Systems (S) Pte Ltd Marcus Evans (M) Sdn Bhd

MEDIA REPRESENTATIVES JAPAN:

Ted Asoshina Echo Japan Corporation Tel: 81-3-32635065 Fax: 81-3-32342064 aso@echo-japan.co.jp

KOREA: Young-Seoh Chinn Jes Media International Tel: 82-2-481 3411/3 Fax: 82-2-481 3414 jesmedia@unitel.co.kr

TAIWAN: Robert Yu Worldwide Services Co Ltd Tel: 886-4-23251784 Fax: 886-4-23252967 sales@wwstaiwan.com The closing date for placing advertisements is not less than

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