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MICA(P) 011/07/2011 | ISSN 0219/5615 | PPS 1561/06/2012 (022743)

Machine Vision | Alternative Energy | Wireless Networking | Industry Eye 2012

The Rise Of Alternative Energy Finance Wireless Set To Surge Industry Eye 2012 Executive Opinion

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contents February/March 2012

ISSUES & INSIGHTS

32

New Generation RISC Processing Power

34

Bloomberg New Energy Finance

In recent years, a new generation of Reduced Instruction Set Computing (RISC) based products are embracing green technology, engendering new business opportunities. By Tony Chen, Advantech

IAA spoke with Michael Liebreich, who is the CEO of Bloomberg New Energy Finance, a company which he founded in 2004, and was later bought by Bloomberg, which became a division of that same company in 2009. By Mark Johnston

Process CONTROL

36

Determining Load Horsepower, Wiring, And Breaker Size For Safe And Efficient Installations

Properly sizing motors for a given load results in driving loads more efficiently and saving money. By Randy Barnett, National Technology Transfer

SOFTWARE & NETWORKS

40

Wireless Meeting Your Needs

44

Pushing Ahead With Wireless

Old and new plants are now starting to make more measurements in order to automate manual tasks, monitor critical assets, and improve productivity. These additional measurements can increase output and reduce operation costs. Wireless is increasingly the solution of choice for deploying these additional transmitters. By Jonas Berge, Emerson Process Management

As Europe and the US battle their economic woes, the Chinese economy is booming. The largest employer in China, with an estimated staff of one million, PetroChina, is pushing ahead with improvements in efficiency, security, and safety. By Mark Johnston

Instrumentation & Measurement

48

Vision Systems: Meeting The Need

52

Machine Vision: Meeting Fast Changing Consumer Patterns

Points to consider when selecting the right automation system for the right production environment. By Didier Lacroix, Cognex

The fast changing consumer patterns of today are paving the way for greater use and implementation of machine vision to aid in the production process. By Maria Carlsson, Sick 2  industrial automation asia | Feb/Mar 2012


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ENQUIRY NO. 364


contents February/March 2012

fEATURES

59

Safety As A Priority

IAA spoke with Paul Gruhn of ICS Triplex, a company acquired by Rockwell Automation. Mr Gruhn is a safety expert and ISA fellow with many years experience in the oil and gas industry. By Mark Johnston

ENERGY

54

Winds Of Change

With the right focus and enabling policies in place, global energy requirements can be largely met by the use of wind turbines. By Amreet Singh

62

Industry Eye 2012: Executive Opinion

EVENTS

66

SCM Logistics World 2011

67

Fluke Predictive Maintenance Seminar 2011

SECTOR SPOTLIGHT

56

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Robotics For Electronics Manufacturing

Electronics manufacturing is crucial to any modern-day economy, given the demand for technology and increasingly sophisticated gadgets. The use of industrial robots promises to take the sector to even greater heights. By Shahnawaz Abdul Hamid

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.

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4  industrial automation asia | Feb/Mar 2012

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EDITOR’s PAGE

Published by:

EASTERN TRADE MEDIA PTE LTD (A fully owned subsidiary of Eastern Holdings Ltd) Managing Director

Kenneth Tan editor

Joson Ng josonng@epl.com.sg

The success of automation to reduce cost and improve safety is an important trend, but it is also worth bearing in mind its consequences. The eutopia imagined of an advanced society with a perfect socio-politico-legal system is the, as it seems, unreachable end point for many nation builders. In the modern context, automation is at the heart of successful societies, undertaking labour intensive tasks and repetitive actions, leaving us to do what we are good at, ie: thinking. As mentioned, as we automate more processes, there will ultimately be less manual labour required from humans, and so we must adapt our societal understandings accordingly. The implications of this vary, but wholly there will be a shift in labour markets, with less emphasis on labour intensive employment. However, change to such a system will be slow, limiting any sizable market impact, but instead increasing levels of safety and decreasing cost of operation for companies. Safety will ultimately be increased through a reduction in human error, and avoiding contact between machinery and human operators, limiting the chance of accidental injury. However, automation is not only limited to relieving workers from labour intense or repetitive tasks, but also as a tool to extend human capability, eg: hazardous areas, monitoring multiple locations, and data collection and analysis. How intelligent these devices and networks get will determine how much we entrust in them to accomplish a task without human supervision. It is a thought worth pondering, and so, we should understand and build effective sociological and management models around this predestined eventuality. As your life becomes more automated, we take a look, in this issue of IAA, at major trends and fields of exciting study in the world of automation today. Fields, such as, green technology, wireless networks, machine vision, and electronics manufacturing. As always, we look forward to your feedback.

Mark Johnston Assistant Editor

Assistant editor

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Derick Chia derickchia@epl.com.sg Sales Manager

Stephen Lim Ee Tak stephenlim@epl.com.sg CIRCULATION EXECUTIVE

Emily Wang emilywang@epl.com.sg Contributors

Tony Chen, Randy Barnett, Jonas Berge, Didier Lacroix, Maria Carlsson, Amreet Singh, Shahnawaz Abdul Hamid Editorial Consultants

Jim Pinto Industry Analyst

Alastair Ross Director, Codexx Associates Ltd

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EASTERN HOLDINGS LTD executive Board Chairman

Stephen Tay GROUP EXECUTIVE DIRECTOR

Kenneth Tan Financial Controller

Robbin Lim

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ENQUIRY NO. 264


Industry News B S K, JKT, Indonesia

Element14 Enhances Technology Leadership In Key Markets Through Agreement With Infineon Technologies

Singapore: Element14 is to become a globally franchised distributor for Infineon Technologies AG, enabling engineers worldwide to take advantage of the company’s semiconductor solutions and element14’s range of customer services and supporting technologies. The agreement allows element14

to strengthen its product offering to its global customer base, delivering the benefits of direct engagement with Infineon and access to their new products as soon as they are introduced. Infineon’s semiconductors and system solutions embody the company’s expertise in technologies such as analogue and

mixed signal, RF, power and embedded control. “We are delighted to be working directly with Infineon, a universally re s p e c t e d a n d m a r k e t - l e a d i n g semiconductor manufacturer,” said Marianne Culver, global head of supplier and product management at element14. “Delivering the Infineon portfolio to our customers throughout the world will enable us to extend our technology leadership in key market segments such as automotive, security and identification, alternative energy and transportation and mobility,” she added. “Establishing this relationship with a global high service distribution partner is an important move forward for both our companies,” said Robert Leindl; CVP distribution and EMS, Infineon. “As a multi-channel distributor with a strong focus on ecommerce, element14 delivers the benefits of a highly effective global marketing and support network, which will help us strengthen our position as the manufacturer of choice for technology innovators everywhere,” he added.

IBM Study: 60 Percent Of ASEAN Chief Marketers Unprepared For Complexity From Digital Era Transformation Singapore: An IBM study of more than 1,700 Chief Marketing Officers (CMOs) from 64 countries and 19 industries, including 70 CMOs from ASEAN, reveals that the majority of the world’s top marketing executives recognise a critical and permanent shift occurring in the way they engage with their customers, but question whether their marketing organisations are prepared 8  industrial automation asia | Feb/Mar 2012

to manage the change. At the same time, the research shows that the measures used to evaluate marketing are changing. While 59 percent of ASEAN CMOs (Global: 63 percent) think return on marketing investment will be the primary measure of the marketing function’s effectiveness by 2015, even among the most successful

enterprises, they feel insufficiently prepared to provide hard numbers. And most of these executives — responsible for the integrated marketing of their organisation’s produc ts, ser vices and brand reputations — say they lack significant influence in key areas such as product development, pricing and selection of sales channels.


Industry News

Singapore: NXP Semiconductors and Bank Mega have announced that they have collaborated to bring a contactless ticketing solution to Trans Studios Makassar and Bandung, two of the world’s largest in-door theme parks. This contactless smart card enables visitors to securely access the theme parks’ facilities as well as make convenient micropayments at retail locations and public services possible. The deployment is one of the largest contactless, multi-application card schemes in Indonesia. The MIFARE DESFire EV1 microcontroller-based technology, which is conventionally used in transport projects, will allow visitors to enjoy the theme park and all of its attractions without using cash or tickets. Visitors can also use the same card for shopping and payment of road toll and car park fees. Bank Mega chose to incorporate NXP’s contactless smartcard technology into the system, accomplishing a high-performance and cost-effective solution that meets the needs of the park operator as well as merchants. The

card functions as an electronic purse, an access management key and a customer program tracker. It improves the visitor`s stay in the Trans Studios by making their transactions faster and more secure, with reduced chances of fraud and human error. The contactless card system also provides Bank Mega and park operators with valuable insights on customers` preference and spending habits. The analysis of this data will allow them to plan and effectively deploy more customer oriented programs in the future. Henri Ardevol, VP and GM, secure transactions, NXP Semiconductors said: “The rich solution developed with Bank Mega proves the full potential of NXP`s multi-application smart card ICs. Modern contactless solutions such as these ensure uncompromised convenience, performance and security for applications like transport, access or micropayment.” Kostaman Thayib, director of Retail Banking from Bank Mega commented: “Trans Studio Makassar, along with Trans Studio Bandung, is the first of many

linno1234, Indonesia

NXP And Bank Mega Bring Contactless Ticketing Solution To In-door Theme Parks

similar theme parks that are planned to be opened in Indonesia over the next few years. With the help of NXP’s advanced MIFARE DESFire EV1 technology platform, we combine high technology with amazing convenience features, making the entire experience more fun and memorable for visitors.” Bank Mega is currently considering launching the contactless card system on a larger scale in other theme parks across Indonesia, utilising the MIFARE DESfire EV1 as the common platform card.

RS Components Extends 3D CAD Library With More Models From Molex And Omron Singapore: RS Components (RS), the trading brand of Electrocomponents, has expanded its online library of free 3D CAD product models. The latest update includes more than 2,000 new models from Molex and Omron. The 3D CAD models from both suppliers are now available for download free-of-charge from the RS website, offering electronics design engineers a simpler, faster route to complete their designs on time. With the release of an additional 1,000 3D models of Molex connectors, encompassing the latest technologies, the range of Molex 3D models available from RS now covers more than 7,000

products. Over 1,000 3D models of Omron parts have also been added to the RS library, including tactile, push button and DIP switches, as well as flow sensors, micro switches and relays. Users now have access to over 30,000 certified 3D CAD models of electronic and mechanical components. Registered users can download a model from the RS website in up to 23 neutral and native CAD file formats, enabling engineers to select the model in their preferred CAD package for mechanical design. Each model has a part number and ordering information attached, aiding the purchasing process and allowing for

quick completion of new designs. Mark Cundle, technical marketing manager for RS Components said: "Producing 3D CAD models can be a time-consuming effort for engineers involved in electronics design. Extending our 3D CAD model range provides our customers with access to the most comprehensive library of online downloadable models in all major CAD file formats, in one place and at no extra cost. This is an essential part of our support for engineers with reliable technical information and online resources that enable them to find, design-in and buy from one source." Feb/Mar 2012 | industrial automation asia  9


Industry News

Henk L, Amsterdam, Holland, Netherlands

Intermec Enters Strategic Partnership With Ecom Instruments

Singapore: Intermec and ecom instruments, a worldwide operating manufacturer of intrinsically safe mobile solutions for over 25 years, have entered a joint partnership to develop and deliver innovative explosion-protected mobile computers ideally suited to hazardous operating conditions. “This partnership will help Intermec further cement its place in the Asia-Pacific

as a provider who can deliver solutions to clients that are actually made for their needs, not just the closest fit,” said Mike Muller, VP and GM for Asia Pacific. “Industrial operations are faced with hazardous environments on a regular basis, yet struggle to use technology due to the safety risks. With Intermec working with ecom, we can negate those risks.” The relationship will leverage Intermec’s rugged mobile computer experience and ecom’s competence in developing portable intrinsically safe devices to bring to market solutions that are approved for use in hazardous areas. Ecom’s technology ensures worldwide certifications for use in explosive atmospheres, ranging from refineries, chemical plants, mining operations and pharmaceuticals, among others. Together, Intermec and ecom will address market demand for innovative mobile computing solutions that can withstand the rigors of use within the most hazardous environments.

"Operational pressures are continually impacting technology buying cycles for hazardous areas as businesses are looking for not only ruggedness and intrinsic safety, but a total mobile solution that enables them to perform efficiently in mission-critical environments," said Rolf Nied, president, ecom instruments. "We look forward to collaborating with Intermec on technology innovations that offer next generation mobility requirements and better empower mobile workers in hazardous areas," he added. “We continue to see strong demand for specialised mobile computers and communications solutions certified for use in hazardous environments with explosive atmospheres. Ecom Instrument’s expertise in hazardous environments combined with Intermec’s rugged handheld solutions represent a strong partnership to address this critical opportunity,” according to David Krebs, VP mobile & wireless at VDC Research.

National Instruments Expands Footprint In Southeast Asia Jakarta, Indonesia: National I n s t r u m e n t s h a s a n n o u n ce d i t s intention to open its first Indonesia of fice in Jakar ta, reinforcing commitments to expand its footprint in Southeast Asia. "National Instruments is ver y pleased to be in Indonesia, Southeast Asia's largest and fastest growing economy. We are commit ted to establishing our presence here as a partner in leading edge research and innovation," said Victor Mieres, VP of sales & marketing for Asia Pacific. Located in Sentral Senayan 2 in Jakarta, National Instruments Indonesia is the latest addition to the company’s worldwide locations, which currently spans over 40 countries. With the Jakarta office, the company will be able 10  industrial automation asia | Feb/Mar 2012

to bring automation and measurement technologies and provide technical expertise to Indonesia-based customers in the government and the defence sectors, in aerospace, mining, oil & gas, and also manufacturing as well as the academia. The Jakarta office opening comes on the heels of initiatives designed to strengthen the company’s presence in Asia. In April 2011, it had also opened a Vietnam office in Ho Chi Minh City. T he company ha s al s o b een increasing its support for regional academia and research institutions. "Indonesia is gaining momentum as a global economic leader. We want to be close to our customers here as they leverage growth in these markets, while at the same time, be accessible to

our long-term industry and academic partners," said Chandran Nair, MD, National Instruments Southeast Asia. Setting up an office in Indonesia will also enable closer ties with the company’s academic partners such as Universitas Indonesia and Institut Teknologi Bandung, and serve to cement active partnerships with nonprofit and socio-civic organisations, such as the United Nations Educational, Scientific and Cultural Organisation ( U N E S CO), w h i c h i s r e g i o n a l l y headquartered in Jakarta. On top of this the company has recently launched an initiative called Science, Technology and Engineering Exchange Laboratory (STEEL) with UNESCO and the Science Centre Singapore.


Industry News

Cisco And Etisalat Strengthen Collaboration By Signing A Memorandum Of Understanding Abu Dhabi, UAE: Cisco, a Information and Communications Technology (ICT) company, and Etisalat, an operator in the Middle East and Africa, have announced that the signing of a Memorandum of Understanding (MoU) to map all strategic mutual objectives between Cisco

and Etisalat. The two companies also announced a Global Frame Agreement to cover all of Etisalat's affiliates that buy Cisco products and services across Etisalat's 18 footprint countries. The signing ceremony was held at Etisalat Headquarters in Abu Dhabi and

was attended by Etisalat Group CEO, HE Ahmad Abdul Karim Julfar, and Cisco's senior VP for Cisco Emerging Markets, Duncan Mitchell. The delegation also included the GM for Cisco UAE, Wayne Hull and regional manager for Cisco UAE, Mohammed Tantawi.

Doha, Qatar: “Future growth in world energy demand is a cause for optimism because it will signal economic recovery and progress,” Rex Tillerson, chairman and CEO of ExxonMobil Corporation said. “By understanding our strengths and proper roles in economic expansion, we can clarify our policy choices, fulfill our core responsibilities and open up economic opportunities for decades to come,” he added. The company is forecasting the global economy to more than double in size between 2010 and 2040, and during that time energy demand will grow by more than 30 percent. In order to meet that demand, the world needs to invest in and develop all economically competitive sources of energy. Projections of significant population growth combined with expanding trade, new technologies, and transformative economic opportunities will drive economic expansion and rising standards of living — particularly in the developing world, Mr Tillerson said in a speech to the 20th World Petroleum Congress in Doha. “The energy and economic challenges the world will face in the decades to come require a business and policy climate that enables investment, innovation and international cooperation. Sound policies and government leadership are critical. When governments perform their roles effectively, the results are extraordinary

— bringing enormous benefits in terms of investment, enterprise, economic growth and job creation,” he added. Mr Tillerson said that the key to unlocking new economic growth was for industry, governments and society at large to focus on their respective roles and responsibilities. “By understanding our strengths and proper roles in economic expansion, we can clarify our policy choices, fulfill our core responsibilities and open up economic opportunities for decades to come,” he said. Government has a responsibility to provide a stable and fair legal, tax and regulatory framework; industry needs to invest with discipline to develop energy in a safe and environmentally responsible way; and the public also has a role to play, Mr Tillerson said. “Citizens and consumers need to understand the importance of energy, the vital role it plays in economic and social development, and how sound policy supports responsible energy development and use. The debates and discussions in society at large need to be informed by the facts and fundamental realities of the challenges before us.’’ Mr Tillerson said the state of Qatar is a leading example of what can be done when policies are in place to enable investment and innovation. “In just over a decade, Qatar has risen to become the world’s leading supplier of liquefied natural gas. In the process, the

kaleff, Sweden

ExxonMobil CEO Addresses 20th World Petroleum Congress

Doha, Qatar

nation has unleashed its own economic growth, supported innovation, spurred job creation and strengthened the energy diversity that allows free markets to maximise the value of national resources for producers and consumers. Qatar is a beacon of energy prosperity.” MrTillerson also said the current economic challenges will not last forever. “There is reason for optimism but it is more important than ever that we swiftly take on these challenges with a sound and principled response,” he said. “History proves that energy policies that are efficient and market-based are the best path to economic growth and technological progress,” he added. Feb/Mar 2012 | industrial automation asia  11


Industry News

Adlink Technology Commits To ARM Development By Joining New Computer-On-Module Initiative Taipei, Taiwan: Adlink Technology has announced it will support the new Computer-on-Module (COM) standard from Kontron for ultra low-power embedded architecture platforms with a whole new line of products. Building on its design experience with ARM/RISC in OEM and intelligent display projects, the first endeavor outside x86 boundaries for a standard form factor company's product offering. The new COM standard provides a very slim and low profile solution for ARM/RISC and System-on-Chip (SOC) based ultra low-power processors. The standard specifically targets new fast growing markets such as handheld devices and industrial tablets, and in the near future is also expected to move into more traditional applications such as industrial control and data communications. It will be based on a 314-pin MXM 3.0 connector that allows for a total package height of less than 5 mm for both module and carrier. Two module sizes are specified: a very compact ‘short’ module measuring just 82 mm x 50 mm and a ‘full size’ module measuring 82 mm x 80 mm. The defined pin-out will be able to support both traditional features, such as, 24-bit RGB, and will be future proof by supporting more modern standards such as LVDS, HDMI and DisplayPort. Power consumption of these ARM/RISC solutions will be on the order of 3W.

"Current COM standards do not address the needs of ARM/RISC specific designs. In the COM market today, we either see ARM being forced onto x86 optimised designs that lack ARM critical pin-outs, or we see specific ARM designs that are not future proof because they lack the inclusion of modern interfaces into their pin-out," explains Dirk Finstel, CTO, at Kontron. He continued: "This limitation in existing COM standards makes our case that there is a need for a new form factor now. We welcome Adlink to join us in the promotion and verification of this new COM standard. Bringing this to the market with a second supporting company emphasises the concept of second source that has made the COM approach so successful during the last 10 years." "Embedded technology has always leveraged parts that have been deployed on a large scale in the commercial field. The reason for this is simple: wide availability, investment in OS support, and optimised pricing for components due to large commercial volumes," according to Henk van Bremen, product director, embedded computing, Adlink Technology. He continued: "This happened with the notebook market in the early 2000s and with netbooks around 2006. It is happening today with the breakthrough of ARM and RISC in the intelligent mobile phone and tablet market that is

taking the traditionally x86 dominated netbook market by storm. For the first time, embedded customers will have the same wide choice of operating systems on ARM as on x86, enabling efficient implementations of new and complementary embedded applications based on ultra low-power devices, that were not possible with x86 based platforms. Adlink will be able to offer a wide range of OS support including: Linux, Android, Windows CE, Windows 8, VxWorks and QNX." The support model for ARM/RISC based design will be very different than that of traditional x86 designs. While drivers for x86 platforms are generic and mostly provided by parts vendors, the loading on ARM/RISC hardware suppliers is much higher. The company is investing heavily in a new infrastructure to be able to provide driver development, customisation and application support that is specifically focused on ARM/RISC for all their product lines, not just for COM modules. The price-to-performance ratio of ARM and RISC will allow the company to offer modular solutions far below the US$100 level, a price point that has been requested for many years in the embedded market, but that was not achievable with x86 based platforms. The company hopes to present early concept models around the end of February 2012, during Embedded World in Nuremberg, Germany.

Kvaser Announces CAN Data Logger With Scripting Functionality Mölndal, Sweden: Kvaser AB has introduced a new high-speed Controller Area Network (CAN) to USB data logger that boasts the ability to run user-developed scripts to suit a wide variety of CAN networking applications. 12  industrial automation asia | Feb/Mar 2012

The company’s Eagle product, a dual channel CAN to standard USB highspeed data logger that is capable of running user-developed scripts to suit a wide selection of CAN bus applications, has been designed with engineers in

mind who need customised features such as CAN protocol converters, CAN gateways, advanced CAN logging functionality, CAN node simulation and standalone ECU programming. As such, the product can be applied to industries


Industry News

as broad ranging as automotive development, industrial diagnostics and oil and gas monitoring. The product’s script functionality allows users to develop highly customised applications written in the company’s ‘t‘ programming language. The programming language, which is event driven and C-like, is compiled into efficient byte code for execution on Eagle on the developer’s PC. The company also has a network of technical associates with different domain expertise who will become a major source of applicationspecific Kvaser ‘t‘ software for Eagle.

Commenting on the announcement, Lars-Berno Fredriksson, president, Kvaser AB, said: “With the Kvaser Eagle platform, we responded to customer requests for a CAN interface that meets the requirements of many different application domains, as well as being applicable to the whole CAN based systems lifecycle; development, integration, verification, after market and maintenance. The result is our most flexible interface yet, which, with a little programming expertise or help from our network of specialist software partners, can be perfectly tailored to the user’s

application in a way that most other CAN interfaces on the market cannot.” Kvaser AB’s marketing director Michael Odälv added: “An important provision for Eagle was the ability to encrypt scripts so that domain developers and users can protect their intellectual property. In addition, our design team made ease of program development central to their efforts, giving software developers the ability to develop the company’s ‘t‘ script using an editor that they are already familiar with and the company’s CANlib software development kit.”

Helsinki, Finland: Metso has developed a new technology with which municipal and industrial wastewater plants are able to improve their performance and reduce the amount of chemicals used in the sludge drying process by even up to one third. The potential users of this innovation include all large wastewater treatment plants in the world. The new technology features an advanced online measurement system for processing sludge, which is an integral part of wastewater treatment. Thanks to a measurement system based on LED and laser technologies, it is now possible to separate dry solids and water from each other more accurately and efficiently than before. In this way, the amount of water treated at a plant can be significantly increased and the amount of chemicals used in the sludge drying process can be decreased by 30 percent. In addition to higher capacity and lower chemical costs, savings are gained as the transportation costs of the dry solids separated from sludge decrease. The further use of the dewatered sludge in energy production is also significantly more efficient, as dewatered sludge contains less water than before. "The new technology developed

Columbus, Ohio, United States

Metso Introduces A Solution For Increasing Capacity In The World's Wastewater Treatment Plants

Wastewater treatement plant

by Metso offers the world's water treatment plants an opportunity to improve their performance and as such gain major cost savings. A large North American wastewater treatment plant has calculated that it saves even up to 30 percent in its annual US$2.5 million chemical costs," says Timo Rantala, product manager, Metso's Automation business line.

"In the f ir s t phase, the new technology will most probably interest especially large wastewater plants in Western Europe and North America, where the level of automation is already high. It is these plants that often have major capacity issues and are under pressure to save costs. Interest in these kinds of solutions is growing in Asia, too," Mr Rantala comments. Feb/Mar 2012 | industrial automation asia  13


Industry News

Nick Benjaminsz, Breda, Brabant, Netherlands

Increased Security Requirements Create 1.8 Billion Unit Market

In an increasingly interconnected world, security requirements continue to increase.

London, UK: Service providers, retailers, banks, governments, and enterprises are increasingly working to counter the growing threat of hacking and identity fraud that made headlines throughout 2011. As a result, vendors of hardware and software solutions aimed at boosting security for online transaction and access are set to commence battle. Cumulative shipments of hardwarebased solutions, including One-TimePassword (OTP) generators, portable smart card readers, and secure USB tokens will reach 1.8 billion units by the end of 2016. However, greater development of more user-friendly software in browsers and on mobile devices will result in software solutions accounting for 60 percent of shipments in 2016. The market will see a boost in growth for USB tokens over the forecast period with OTP generators experiencing a decelerating growth pattern due to high profile hacks to companies such as RSA, reducing OTP credibility. Overall, the market remains positive, with hardware and software solutions shipping in excess of one billion units in 2016 alone. Phil Sealy, research analyst, ABI

Research, says: “High profile hacks have gained extra media attention and coverage, heightening awareness of what a data compromise can mean. Hacks have not been limited to one particular market. RSA, Sony, Citigroup, L-3 Communications, and NASA have all fallen victim in 2011.” An explosion of mobile software solutions shipping into the market will occur from 2013 onward. This should be no surprise, with an increasing number of smartphones and tablets being utilised to access networks, complete transactions, and manage email. With threats growing, mobile software solutions are forecast to achieve the greatest growth, with annual shipments of 392 million in 2016. John Devlin, group director, ABI Research, comments: “The market is picking up and will experience growth over the coming years. The cost of compromise is being realised. Companies are looking at deploying solutions not only to protect data, but also to limit the possibilities of damaged credibility while maintaining services which are not only safe, but also accessible to consumers on a 24/7 basis.”

Iberia Implements Amadeus Solution For The Distribution Of Ancillary Services Madrid, Spain: Iberia, Spain’s largest air transport group, has adopted Amadeus Ancillary Services to distribute its ancillary programme to travel agencies. The solution is launching in Spain where travel agents can now offer advanced seat selection to their customers. The new service enables travellers to book their preferred seat prior to the checkin process — when seats are generally assigned — and includes an option to choose preferential seats such as those in the exit row. The Amadeus ancillary solution is also integrated across Iberia’s call centre and sales offices so that customers can be consistently served 14  industrial automation asia | Feb/Mar 2012

across these channels. “By adopting the Amadeus solution we now have the technology structure that will enable us to execute our ancillary services strategy in the long-term,” said José Arribas, head of commercial logistics, Iberia. “We have worked with Amadeus for some months to bring this technology to our travel agencies so that they can offer our services to their customers and reinforce their role as travel consultants. This is yet another proof point of our commitment to work with our travel agency partners,” he added. Travel agencies in Spain are now able to book the advanced seat

selection option with the Electronic Miscellaneous Document (EMD) industry standard. The electronic messaging tool facilitates the issuance, management, distribution and fulfilment of the ancillary services. As with the electronic ticket in 2007, the EMD is part of the e-Services IATA initiative to eliminate the use of paper and ease processes. Amadeus has integrated an interactive catalogue in its travel agency selling platform which displays the range of airline optional services available. In this way, the travel agent can view, book and up-sell ancillary services quickly and efficiently. The


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content of the catalogue — the service and its description — is controlled by the airline, which will use this space to differentiate its offer. “Our ancillary solution enables airlines to merchandise their services to travel agencies as they would do through other sales channels, but also to generate additional revenue by making the booking process as efficient

and straightforward for the travel agent to use,” said David Doctor, director of distribution marketing, Amadeus. Recent analysis by Ideaworks, a consultancy company for the airline industry, estimates that airline ancillary revenue will soar to US$32.5 billion worldwide in 2011. According to this study, ancillary revenue lifts the airline industry from a loss making

position and continues to provide a very effective hedge against runaway fuel bills. Seventeen other airlines have signed up for Amadeus Ancillary Services. The solution has already been implemented both for online and travel agency channels in key markets, including France, the Netherlands and Scandinavia.

Zurich, Switzerland: ABB’s global business for Marine and Cranes continued to expand in 2011. To better serve the needs of the marine automation and control system market, the company established a global vessel information and control organisation to develop automation solutions specifically for marine applications, based on the company’s process automation technologies. The company’s expanded portfolio of solutions for Marine Automation and Control systems consists of a broad range of marine advisory and fleet management reporting solutions, integrated automation, vessel management and control systems, and marine instrumentation and sensors, all of which help to optimise vessel operations and performance, improve energy efficiency, onboard equipment reliability and availability, and operational safety. The demand for upgraded vessel information and control systems has increased, as ship operators must be ready to meet new environmental regulations, while they lower onboard energy use and fuel consumption. The company’s automation and control technologies provide the visibility and control needed to achieve these goals and improve operating costs. Using the company’s automation solutions that have helped customers 16  industrial automation asia | Feb/Mar 2012

Rodolfo Belloli, Italy

ABB Strengthens Position In Marine Automation And Control Business

Marine industry, big business for ABB.

throughout the process industries improve their operational efficiency, energy efficiency, asset availability and overall safety, the company will further develop specific versions of these solutions for the needs of the marine industry, for use in offshore and merchant vessel applications. "ABB will expand our offering to include marine automation and

advisory systems based on our industry experience and technology," said VeliMatti Reinikkala, head of ABB’s process automation division. He continued: "This strategic move is part of our 2015 growth strategy; ABB's experience in process automation technologies helps us to redeploy these successful industry proven solutions to help our marine customers."


Industry News

North Carolina, US: The Automation Federation announced that, in October 2011, the Society of Manufacturing Engineers (SME) signed a Memorandum of Membership, becoming one of the newest members of the Automation Federation. The Automation Federation is an association of member organisations that provides awareness, programs and services that continually advance all facets of the automation profession. The Automation Federation serves as the ‘Voice of Automation‘ by providing advocacy and industry-wide strategic analysis and coordination through its member organisations. SME is a professional society that advances manufacturing knowledge and influences more than half a million manufacturing practitioners annually. The Automation Federation and SME aim to work together to promote

Science, Technology, Engineering and Mathematics education (STEM) and the Automation Competency Model to improve the general public’s awareness of automation and technology and to help small manufacturers around the country remain competitive. “The Automation Federation puts a great deal of effort into communicating the importance of STEM to the next generation of automation professionals,” says Mike Marlowe, MD, Automation Federation. “We recognise that the collaboration with SME empowers the Automation Federation with a larger pool of resources to help us reach our audience and enhances our programs,” he added. Mark Tomlinson, SME executive director commented: “SME and the Automation Federation are dedicated to working together to promote and

shho, Melbourne, Victoria, Australia

The Automation Federation And The Society Of Manufacturing Engineers Sign Memorandum Of Membership

advance the automation profession through education, new technology development, sharing our best practices and improving the quantity and quality of the automation workforce for the benefit of the manufacturing industry. Between the two organisations, we reach over half a million manufacturing practitioners, and by partnering, we leverage each other’s respective strengths. We look forward to working with the Automation Federation and its partner organisations as long as possible.”

Neutral Tandem Lands On Forbes’ America’s Best Small Companies List Chicago, US: Neutral Tandem, a provider of global interconnection services, has announced that Forbes Magazine , has named the company #38 on Forbes’ list of America’s Best Small Companies. The rankings are based on earnings growth, sales growth and return on equity in the past 12 months and over the past five years. Stock performance versus a group of peers was also factored into the ranking. The company has earned these rankings by posting 48 percent sales growth over the last five years on average, and sales of US$242 million over the last 12 months as of September 2011. The company continues to be

poised for success in the future by streamlining the interconnection of voice, IP Transit and Ethernet services to over 700 carriers and service providers worldwide. “This past year we have focused on expanding our product portfolio to meet the growing demands of our global customer base,” comments Ed Evans, CEO, Neutral Tandem. “The launch of EtherCloudSM, our global end-to-end Ethernet delivery platform, and our recent announcement on Hosted Collaboration Service, are examples of how we are developing complimentary services to enhance our product line and expand our addressable opportunities,” he added.

According to Forbes, the list of the 100 Best Small Companies in America features, “Outfits with remarkable sales and earnings growth across industries. Candidates must have been publicly traded for at least a year, generate annual revenue between US$5 million and US$1 billion and boast a stock price no lower than US$5 a share. (For apples-to-apples comparisons we excluded financial institutions, REITs, utilities and limited partnerships.)” Shares of last year’s members rose 10 percent on average, beating the Russell 2,000 small-company index by 10 percentage points.

Feb/Mar 2012 | industrial automation asia  17


Industry News

Rockwell Automation Integrated Architecture Delivers New Dimension Of Scalability Applications Milwaukee, US: Rockwell Automation has expanded its Integrated Architecture portfolio for smaller applications with a series of scalable, Allen-Bradley CompactLogix Programmable Automation Controllers (PACs), servo drives, I/O, visualisation and simplification tools. With high-performance features such as integrated motion, safety, EtherNet/IP connectivity and re-usable development tools, the company gives users the ability to standardise on a single control platform for small to large-scale applications. The Rockwell Automation Integrated

Architecture features the Allen-Bradley ControlLogix and CompactLogix controller families. The ControlLogix PAC is suited for applications that have up to 10,000 I/O and 100 axes of motion. The CompactLogix family, meanwhile, is ideal for applications with fewer than 200 I/O and up to 16 axes of motion. Featuring integrated motion on EtherNet/IP, the CompactLogix controller family can provide the same performance, flexibility, reduced development time and ease-of-use as larger scale systems from the company.

Cummins Power Generation Announces Price Increases on Certain Products Globally Minneapolis, US: Cummins Power Generation has announced a general price increase, effective January 1, 2012. The price increases of up to three percent are for dieseland gas-fueled generator sets, automatic transfer switches and other products. The price changes are in response to global market conditions, significant increase in fuel costs and foreign exchange rates.

Plans Announced To Simplify The Delivery Of Ethernet Services For Network, Cloud And Financial Communities Hawaii, US: Equinix, a provider of global data centre services, and Neutral Tandem, a provider of global interconnection services, has announced plans to offer participants of the Equinix Carrier Ethernet Exchange (ECEE) a single point of contact for managing the complexity associated with global, exchange-based, end-to-end managed Ethernet services. Equinix will offer ECEE participants the option to utilise Neutral Tandem’s EtherCloudSM Layer-2 connectivity network and platform to streamline and accelerate Ethernet service delivery into new markets. The company’s   global footprint offers regional operators and multi-national carriers a channel for expansion into over 70 countries, including tier-two and tier-three markets. Utilising the company’s EtherCloud service, ECEE participants are able to save time and reduce complexity with a single source for managing multicarrier local loop arrangements, E-NNI agreements, service provisioning, SLAs, and more. 18  industrial automation asia | Feb/Mar 2012

The planned combination of ECEE and the company’s EtherCloud platform is aimed at addressing the needs of customers in the network, cloud and financial services markets, enabling them to capitalise on higher-margin Layer 2 and Layer 3 services as they expand into new markets. “Carriers with significant expansion plans in regions where they have limited presence need to understand the reach afforded by different Ethernet exchange providers, and weigh this against other approaches,” said Scott Morrison, managing VP, communications service provider markets, Gartner Research. The company selected Equinix to propagate its EtherCloud offering due to the reach of Equinix’s interconnection business across multiple business ecosystems, including financial services and cloud. “Neutral Tandem’s proven track record with interconnecting carriers, combined with Equinix’s strategic data centre locations, will form an attractive

combination,” said Surendra Saboo, president and COO, Neutral Tandem. “With this planned collaboration, Equinix customers will be able to leverage Neutral Tandem’s expansive network, while our customers will have access to the hundreds of customers in Equinix’s strategic IBX locations.”

Relocation Notice With effect from November 23, 2011, Pruftechnik South East Asia has relocated to the address below: Pruftechnik South East Asia Pte Ltd 61 Alexandra Terrace #05-03 Harbourlink Complex Singapore 119936 The company’s contact numbers and general email remain unchanged: Tel No : (+65) 6382 0662 Fax No : (+65) 6382 0776


ENQUIRY NO. 360


Industry Updates

Profinet Continues To Extend Its Leading Position Profinet is ‘a must’ for innovative automation products. More and more manufacturers and users are choosing it for Industrial Ethernet systems. Today, no other Industrial Ethernet solution is supported by so many manufacturers as Profinet. Over 150 manufacturers are already making use of the versatility of Profinet in their devices. For users, this means a large selection of products for their applications and the certainty of relying on an open and future-proof standard. Of course, this trend is also reflected in the number of devices sold. Accordingly, PI can report strong growth in the area of Profinet. A projection of the current node count indicates that well over four million Profinet devices will be installed in the field by the end of this year. Jörg Freitag, chairman of PI, is convinced that the 10 million mark will be exceeded as early as 2014. “Profinet has enjoyed a firstclass reputation within the world's leading industrial companies for many years. Even the choice of an industrial communication standard depends on a long-term outlook. Choosing Profinet is a decision for the future. The large number of manufacturers and products

guarantees long-term investment protection. The number of Profinet devices in use will multiply to over 10 million by 2014,” said Jörg Freitag, chairman, PI. PI is also able to report market growth for Profibus. By the end of 2011, more than 40 million Profibus devices will be installed in industrial plants worldwide. This number shows that user confidence in Profibus is as high as ever.

The inter national network of PI contributes significantly to the success of Profibus and Profinet. With representation on all continents, PI is the world's largest and most influential interest group in the area of industrial communication. A total of 27 Regional PI Associations (RPAs), 43 competence centres, 23 training centres, 10 certification test labs, and more than 1,400 member companies apply their experience and knowledge to PI technologies. “Our network gives our member companies throughout the world a decisive competitive advantage,” explains Mr Freitag. “Here, we have a consistent and straightforward objective: to support the user with the best solution,” he added. ENQUIRY NO. 1101

Jörg Freitag, chairman, PI

500th Profinet Certificate Awarded To GE GE Intelligent Platforms announced that the company was awarded with the 500th Profinet certificate by PI (Profibus & Profinet International) at a press conference at the SPS/ IPC/Drives exhibition in Nuremberg,

20  industrial automation asia | Feb/Mar 2012

Germany. The certified product is the VersaMAX Profinet IO scanner. Marcel van Helten, GM of GE Intelligent Platforms, Germany, and CCS product manager says: “Due to the collaboration with PI we can

increase our flexibility, configuration options and application availability and meet our commitment to open standards.” Joerg Freitag, chairman of PI points out: “The certification is mandatory for


ENQUIRY NO. 369


Industry Updates

Profinet devices in terms of quality assurance. Due to this high quality standard, application users can trust a solid certified portfolio of devices for reliable interoperability. For some time now we have experienced an enormous rise in certification testing for Profinet products. We are delighted about the global commitment of GE Intelligent Platforms in the Profinet environment.” Profinet is now available on the h i g h p e r f o r m a n c e PA C S y s t e m s controllers and the VersaMAX I/O range of products.

Utilising Profinet combined with PACSystems, GE is providing all of the benefits of an Ethernet system without the complexity. The newly designed Profinet VersaMAX I/O node has a redundant power supply option to support the high availability architecture. Name-based configuration enables solutions in just minutes. Built-in switches with a choice of copper or fibre cable types for direct connection means that no extra hardware is needed for connectivity, allowing long distances between

I/O nodes and increased reliability. The adoption of Media Redundancy Protocol (MRP) in a ring topology allows customers to take nodes offline for maintenance without ever shutting down the application. In the event of a wire cut, the system redirects traffic in as low as one millisecond without disrupting the I/O. “PACSystems is known for its high availability offering and the Profinet extensions add significantly to that capability,” said Mr Van Helten. ENQUIRY NO. 1102

Texas Instruments Integrates Profibus And Profinet Even the choice of an industrial communication standard depends on a long-term outlook. Choosing Profinet is a decision for the future — Jörg Freitag, chairman, PI Texas Instruments (TI) has long provided support for integration of PI technologies in various processors for industrial use. With the availability of the new AM 335x processor family, integration of Profinet at the hardware level is now also possible. This will increase the performance of automation devices in terms of both communications and applications while reducing the effort for Profinet integration. A high-performance IRT 2-port switch can be realised based on the integrated ‘Programmable Realtime Unit (PRU)’. The preprocessing of communication in the PRU means

22  industrial automation asia | Feb/Mar 2012

that more processing power is available for applications. The highperformance, ARM-based processor can process complex applications and communication simultaneously, as such, enabling cost-effective integration of Profinet. The Profinet firmware stack of Siemens is used to integrate Profinet f u n c t i o n s . A s a re s u l t , d e v i c e manufacturers can easily access the wide variety of available Profinet functions. Matthias Poppel, European director of embedded processing marketing & applications at TI, said: “Support for Profibus solutions has been in

place since the introduction of our AM1810 microprocessor one year ago. With the integration of Profibus and Profinet technology in the new AM335x ARM-Cortex A8 microprocessor, TI is extending its involvement in the industrial automation market.” Uwe Ruttkamp, director for SIMATIC product and system management, Siemens AG, said: “For many years, Profinet device manufacturers count on the experience and the know-how of Siemens. Besides its own ASICs, firmware and development packages Siemens supports the development of Profinet devices with competent consulting services and technical support. As a result of the long-time participation in the standardisation committees of the PI, Siemens obtained comprehensive Profinet expertise both, for the development of its own products as well as for innovative technology projects, for example in co-operation with TI.” ENQUIRY NO. 1103


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Power loss poses a threat to the equipment, people, and processes you rely on. And with today’s stricter security and safety regulations, process automation,


Newsdesk

Partial Networking

Reduces CO2 Emissions The automotive industry is under pressure. The CO 2 emissions generated by cars has to be reduced. In Europe, Euro six regulations will replace Euro five in 2014, and the average CO2 emissions limit will fall to 95 g/ km by 2020. Chinese 4 standards, similar to Euro 4, came into force in China in 2011 and the city of Beijing is planning to adopt Chinese 5. In the US, Corporate Average Fuel Economy (CAFE) requirements for passenger cars will increase from 30.4 to 37.8 mpg by 2016 and 50.6 mpg by 2025. To meet these increasingly stringent regulations, while Electronic Control Units (ECU) become more complex and consume increasingly more energy, car makers are pursuing many ways to improve fuel efficiency. However, most of the ECUs are powered even in times when their functions are not required. Many of the ECUs are needed quite rarely. This means, partial networking is a solution: All not yet required ECUs are going into sleep mode and can be awaken individually, when their function is really needed. Transceiver Chips A consortium of car makers and 24  industrial automation asia | Feb/Mar May 20092012

Delegates on stage in Qingdao, China.

New chip technology for the automotive industry, enabling a continued reduction in CO2 emissions.

semiconductor manufacturers has pre-developed a specification for high-speed, low-power transceiver chips with additional partial wake-up functionality. These transceivers will be compliant to ISO 11898-2 and ISO 11898-5. The consortium h a s a l re a d y s u b m i t t e d i t s specification to the International Standardisation Organisation (ISO), which will review the submitted document and publish it as ISO 11898-6 international standard. The ISO process for the development of international

standards of the CAN partial networking specifications has already been started. As chairman of the consortia, C&S group has actively contributed to establish t h e re q u i re m e n t s f o r C A N transceiver with selective wakeup functionalities. In the related ISO task force, C&S acts as the chief-editor in order to guarantee a smooth adopting process when converting the document into an ISO standard. The First Silicon Although the partial wake-up standard is under development,


the first chip makers have announced CAN transceiver chips with this functionality. Elmos (Germany) was the first one: The E520.13 transceiver, announced in 2010, realises CAN partial network operation. The partial network mode makes it possible to individually activate ECUs whose permanent operation is not required. If for example ten ECUs in a vehicle are designed for partial network operation, CO2 emission can be reduced by approximately 0.5 g/km. The chip has been already pretested in a vehicle by a German car maker. The IC represents an HS-CAN transceiver according to ISO 11898-5, featuring remote wake-up by means of an individually configurable WakeUp Frame (WUF), in addition to the usual wake-up sources. If the transceiver is directly batterysupplied in par tial network operation, as is common practice in sleep-mode operation today, all other components of the ECU can be deactivated. The partial network transceiver monitors the bus traffic, analyzes it down to the bit level, and responds to the control device’s individual wake-up message. In this partial network mode, the power input of the control device is below 500 µA. One application example is the seat ECU: If the function of this ECU is selected, the device is activated selectively for the period of time required for operation. Other candidates for partial wake-up are the trailer, door, air-conditioning, rear-view camera, auxiliary heating, and power sunroof ECUs. The tasks of filing and re a d i n g o u t t h e i n d i v i d u a l wake-up message, configuring parameters and controlling state transitions are facilitated by an Serial Peripheral Interface (SPI)-compatible interface to

the ECU’s micro-controller. The transceiver chip guarantees that both partial network transceivers and conventional high-speed CAN transceivers according to ISO 11898-5 can be operated together in one network (interoperability). The Second Partial Networking ICs NXP launched an ISO 11898-6 compliant transceiver at the end of the 2011 summer. The TJA1145 transceiver is the response to a government call around the world for a reduction in CO 2 emissions from vehicles. Car makers are increasingly focused on finding ways to produce more environmentally friendly vehicles. As such, car manufacturers are now pushing for CAN partial networking to become an industry standard via ISO and the AUTomotive Open System ARchitecture (AUTOSAR). The stand-alone TJA1145 CAN transceiver and system basis chip UJA1168 — the world’s first highly integrated solution to support CAN Partial Networking — gave design engineers precision control over a vehicle’s bus communication network. By de-activating those ECUs that are currently not needed, engineers are able to significantly reduce vehicle fuel consumption and CO2 emissions without sacrificing performance or consumer experience. TJA1145 and UJA1168 are nextgeneration networking solutions, which combine analogue circuitry and high-density digital circuits. The TJA1145 is a high-speed CAN transceiver, while UJA1168 is a CAN system basis chip with 5 V / 1 0 0 m A m i c ro - c o n t ro l l e r supply. Both support CAN partial networking by enabling ‘Selective wake-up’ and ‘Selective sleep’ functionality. Both chips come with a footprint based on the HVSON14 package. For backwards compatibility reasons, the TJA1145

is also available in a SO14 package. Engineering samples for TJA1145 and UJA1168 are available with volume shipping in 2012. The Third Chip Claiming ISO 11898-6 Compatibility ST Microelectronics (France) has announced the L99PM72PXP, which will support partial networking functionality as described in ISO 11898-6. “Authorities worldwide are setting progressively tougher environmental performance targets for new cars, and car makers must maximise efficiency throughout the vehicle in order to comply,” said Marco Monti from ST’s Automotive Electronics Division. “Integrating new partial networking provides a head start of around 2 g/km CO2 in the drive to meet the new standards,” he added. The chip is housed in a PowerSSO-36 package and is scheduled for volume production in fall 2012. By integrating both High-Speed CAN (ISO 11898-6) and LIN physical layers, it provides all the functions to connect ECUs for car body applications to the in-vehicle networks. Its features are tailored to particular uses such as in climate control modules and door control units, as well as seat modules, trunk and trailer modules, sunroof and rear-view modules. Advanced fail-safe functionality is an additional feature, which improves the sustainability and reliability of ECUs. Built-in features such as supervision of the micro-controller, supply v o l t a g e s a n d t e m p e r a t u re s provide protection against causes of failure. In addition, peripheral functions such as high-side and low-side gate drivers, operational amplifiers and voltage regulators reduce the number of external components and lower overall system costs. ENQUIRY NO. 1104

Feb/Mar May 2009 2012 | industrial automation asia  25


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Texas Instruments Release EtherCAT Microprocessor

The Texas Instruments Sitara microprocessor with EtherCAT slave inter face, orginally announced in April 2011, is now available to the market. The first, and so far only, standard microprocessor product line with hardware-integrated realtime Ethernet is a reality. In line with that release, Beckhoff has adapted the EtherCAT Slave Protocol Stack and provides it free of charge for download. “The announcement of the Texas Instruments Sitara product line with integrated EtherCAT interface gave our technology another boost. Now the first of these chips are available, which 28  industrial automation asia | Feb/Mar 2012

will open additional doors for EtherCAT, both within the classical automation market and beyond,” says Martin Rostan, ETG executive director. Matthias Poppel, director of Embedded Processing for EMEA at TI, adds: “I am pleased that Beckhoff, at the same time, provides the slave protocol stack and, as such, this reference implementation also supports our integrated EtherCAT Slave Controller on the Sitara AM355x from day one. This stack developed by the EtherCAT inventor ensures compatibility. With the integration of the flexible real-time Ethernet and the powerful ARM Cortex A8

CPU, our customers can cover a wide range of automation applications within one chip. Due to the 45nm process technology of the AM335x, one can implement an EtherCAT node with less than 500mW power consumption.” Beckhoff Provides Slave-Protocol Stack Free Of Charge The Slave Stack Code (SSC) from the company is the most used protocol stack for the implementation of EtherCAT slave devices and is therefore considered to be the unofficial reference. The C-code package not only comprises the software part of the EtherCAT


slave interface, but also contains sample applications for drives and I/O devices as well as a tool that helps the developer to adapt the code to the required functionality. The SSC has been available since 2004 and has since been continuously maintained and enhanced. Now it was modularised, so that it became independent of the EtherCAT Slave Controller hardware and can be used with the new TI processor. So far the SSC has been shipped with the company’s slave implementation kits; with the availability of the Sitara product line with EtherCAT interface ETG members now can download the stack free of charge. System Control Fair, Tokyo EtherCAT was a hot topic at Japans largest automation show, the System Control Fair. Several Japanese vendors released new EtherCAT based product lines, which generated extra traffic at the EtherCAT Technology Group booth. At the booth, short EtherCAT introductory presentations were held throughout the day. In addition, an EtherCAT seminar

was held, which also drew a large crowd. Award For Yasuhiko Tabata The ETG Task Force Japan coordinates and co-sponsors EtherCAT marketing activities such as joint trade show booths, i n t ro d u c t o r y s e m i n a r s a n d articles. It was ‘Task Force’ since it was formed originally as a temporary group assisting the ETG office Japan. The group was renamed, and is now called the ETG Regional Committee Japan. The committee consists of the ETG member companies Algo Systems, Beckhoff Japan, Hitachi IES, Nagano Oki, Omron and Sanyo Denki; it meets once every month. At this meeting, the task force had to say good bye to its chairman, Yasuhiko Tabata, who unfortunately had to resign due to health issues. Tabata-san is a passionate EtherCAT supporter; he received an award for his most valuable contribution to the EtherCAT success story in Japan. The group wished him well and hopes that he will recover quickly. EtherCAT Plug Fest Japan Twenty-one developers met in Yokohama for the EtherCAT Plug Fest Japan, testing the interoperability of masters from

EtherCAT Plug Fests are interoperability test events where developers meet to test the cooperation of their devices with others.

four different vendors with the variety of slave devices from eight different vendors. Like all EtherCAT Plug Fests, this second one in Japan proved not only to be a valuable interoperability meeting, but also a great forum where developers can exchange ideas and meet the ETG experts. In total, ETG has so far organised 19 such Plug Fests. In Europe there are two events annually, and one each in Asia and North America. ENQUIRY NO. 1105

EtherCAT was a hot topic at the System Control Fair.

The ETG Regional Committee Japan presents its outgoing Chairman, Yasuhiko Tabata, with an award for his contribution to the EtherCAT success story in Japan.

Dec 2010/Jan Feb/Mar 2011 2012 | industrial automation asia  29


Fieldbus Foundation Announces First Participant In Foundation Development Services Provider Program The Fieldbus Foundation has announced that Softing Industrial Automation, an independent and global provider of hardware and software for industrial automation and automotive electronics, is the first company qualified under its Foundation Development Services Provider (DSP) program. This program helps automation vendors get started with Foundation product development by making it faster-and easier-to bring fieldbus equipment to market. The Fieldbus Foundation launched the Foundation DSP program to assist automation equipment suppliers preparing to design and manufacture products employing Foundation fieldbus technology. The program is intended to provide access to qualified development services providers with the know-how to make fieldbus solutions a reality. Qualified DSP participants have been evaluated to ensure they have the tools, training and experience necessary to support a wide range of Foundation fieldbus development projects. Services that can be qualified in the Foundation DSP program include H1 and High Speed Ethernet fieldbus device development services, as well as host system services. Fieldbus Foundation managerfieldbus products, Stephen Mitschke, commented: “A growing number of Fieldbus Foundation members want to enter the expanding Foundation fieldbus technology market. However, 30  industrial automation asia | Feb/Mar 2012

some organisations may view fieldbus device development as a daunting task when they have little experience or knowledge of digital bus technology. Due to limited resources, they may be required to outsource a portion of the development process. This is where the Foundation DSP solution steps in.” Mitschke added: “From small developers looking for assistance on a few key components, to multi-million dollar companies seeking a partner to develop an entire Foundation-ready device, Foundation DSP can help streamline product R&D. Best of all, the program can ensure a strong Return-On-Investment (ROI) by reducing staffed man-hours and maximising the efficiency of product development.” Dr Ernst Flemming, business development manager, Softing Industrial Automation, said: “For Softing it is key to be known to manufacturers who are interested in utilising Foundation technology. T h e F i e l d b u s F o u n d a t i o n ’s development services provider program is an excellent platform to increase our visibility in this market. The stringent rules that apply to the program ensure that only high-quality technology providers participate in the program. We very much appreciate the recognition at such a high quality level and look forward to seeing the first results shortly.” Foundation DSP program participants and their development

tools/services will be featured in a special section of the Fieldbus Foundation’s website. Participants are also authorised to display the official Foundation DSP logo in their marketing materials. ENQUIRY NO. 1106

Remote Operations Management The Fieldbus Foundation unveiled its Foundation for Remote Operations Management (ROM) solution at a media event held Thursday, December 1, 2011, at the Fieldbus Centre at Lee College, Baytown, Texas. Representatives of the control & instrumentation trade press learned how Foundation technology would transform the industrial remote operations market by providing a single integrated infrastructure built specifically for process automation. The Fieldbus Foundation’s Foundation for ROM initiative is intended to develop a unified digital infrastructure for asset management in remote applications ranging from tank farms and terminals to pipelines, offshore platforms, and even original equipment manufacturer (OEM) skids. The technology enables fieldbus connectivity to remote I/O and the leading industrial wireless protocols, including WirelessHART and ISA 100.11a. It provides an interface to these wireless technologies and uses Electronic Device Description Language (EDDL) and function blocks to ensure interoperability with Foundation for ROM devices. ENQUIRY NO. 1107


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ENQUIRY NO. 378


issues & insights

New Generation

RISC

In recent years, a new generation of Reduced Instruction Set Computing (RISC) based products are embracing green technology, engendering new business opportunities. By Tony Chen, product manager, RISC embedded core group, Advantech

A

ccording to statistics, starting from the 1960s, the electronic technology and market core products show significant trend variations every 10 years. In the past 20 years, the PC, the notebook and the Internet have brought profound changes in our daily lives. At the same time, the evolution of wireless data transmission technologies, which include WiFi, GPRS, 3G, 4G, WiMAX, Long Term Evolution (LTE) and other wireless networks, has greatly strengthened the link between people and information. This evolution of technology has brought more flexibility and convenience to our lives. In the past few years, the 32  industrial automation asia | Feb/Mar 2012

dima v, re, il, Israel

Processing Power

best-selling RISC-based products such as smart phones, tablet PCs, e-books, and Wii have had a tremendous impact on many facets of our everyday lives. Along with the evolution of RISC computing technology, the functions are getting more efficient and powerful. RISC has already benefited our lives in different ways. What is RISC? What is RISC all about? What is the difference between RISC and x86 architecture? RISC is an acronym for Reduced Instruction Set Computer; it is a microprocessor that is designed to perform at a lower number (compared to x86) of computer instructions so that

it can operate at a higher speed. Computer technology started over 30 years ago in the early 1970’s. Engineers observed that 80 percent of computing execution was handled by only 20 percent of the instructions, which meant that a high number of instructions basically went to waste. As such, the RISC concept was developed to reduce the size of the instruction set — and a number of littleused instructions were removed. Afterwards, several RISC designs emerged in the market. What are the typical characteristics of RISC architecture? RISC architecture makes use of a small set of simplified instructions in an attempt to improve performance. It has a smaller ‘die-size’ that requires fewer transistors. They can be designed faster because the simpler RISC-based processor requires less design and application programming effort, and offers lower design costs. But low-cost, performanceimproving, RISC technology is not without its drawbacks. Since the instruction set of a RISC processor is reduced, some functions are not supported and performance is reduced as well. As such, previous RISC products are not suitable for implementation on a general-purpose computing core platform. RISC Product Features Because the instruction set is reduced, it simplifies the CPU architecture and makes the chip die size smaller, with less power consumption per chip, and a higher production quantity per wafer. That is why the RISC solution has the general advantages of lowcost and power-savings. Since the instruction set has been reduced, RISC-based products have performance limitations and in the past were not suitable for use in general applications.


TM and progressed to ARM9 TM and ARM11 TM, on up to the 2008 Cortex TM series. Products based on these processors have enjoyed an enthusiastic market reception. By any measure, the Cortex TM is a masterpiece; it is designed around advanced, high efficiency, multi-issue superscalar, out-of-order, speculating 8-stage

pipeline, and it targets consumer, networking, enterprise, and mobile applications. Even with its expanding functionality, increasing number of processor cores, and expanded performance, ARM has managed to maintain its power efficiency. ENQUIRY NO. 1201

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Currently, RISC has three major IP suppliers - ARM, MIPS & PowerPC. Each has its own characteristics and flexibility. PowerPC is a standard RISC architecture developed by the IBM, Motorola, and Apple alliance known as AIM. It was originally intended for personal computers, but later on became popular as an embedded and high-performance processor. Everybody knew very well that the heart of Apple’s Power Mac G5 was IBM’s PowerPC G5 CPU. Back then, the Power MAC G5 was touted by Apple as the fastest personal computer ever built. The second most common RISC microprocessor is the MIPS. After being acquired by Silicon Graphics, MIPS technology has been widely used in mobile consumer electronics, digital e n t e r t a i n m e n t , w i re d a n d wireless communications, and networking. Last, but not least is ARM, the most successful RISC. ARM targets embedded and low-power segments, and the low end PC market. The relative simplicity o f A R M p ro c e s s o r s m a k e s them suitable for low-power applications. This has made them dominant in the mobile and embedded electronics market. ARM may be aiming to scale up to the laptop market, then desktops, and in the future, servers. What are the attributes that made ARM a success in the market? After much thought and consideration, there are three major points: • Performance grew 10 times within a few years. • The continuous optimisation approach achieved ever lower power consumption. • Full software compatibility was, and is, preserved even for future enhancements. The technology in the ARM CPU core started from the ARM7

Feb/Mar 2012 | industrial automation asia  33


issues & insights

Bloomberg New Energy Finance

A

lternative energy sources are increasing, and while such events as Europe’s dept problem will hamper growth in the short term, the need and importance of finding alternative sources of energy and developing them to their fullest will continue to push the industries development through difficult times. IAA: What is Bloomberg New Energy Finance? Michael Liebreich (ML): New Energy Finance is a company that I founded in 2004 and grew it until 2009, then subsequently sold it to Bloomberg, we are now a division of Bloomberg. What we do is news, data, analyse, price indices, and events. It is all the things that you need to support decisions, whether you are a policy maker or an energy company, or an equipment manufacturer in clean energy, or an investor in clean energy. We provide the tools to support those decisions. New Energy Finance does not provide finance, we are part of Bloomberg, so it is all about information and analyse. The company consists of 200 people, in total around the world, including journalists, data management people, analysts and the commercial team. The break-up is roughly 100 people in the UK and 100 in Asia, Latin America, South Africa, and then North America.

34  industrial automation asia | Feb/Mar 2012

Singapore International Energy Week

IAA spoke with Michael Liebreich, who is the CEO of Bloomberg New Energy Finance, a company which he founded in 2004, and was later bought by Bloomberg, which became a division of that same company in 2009. By Mark Johnston IAA: What was your motivation in founding the company? ML: I spent sometime to figure out what I was going to do next, I came to the conclusion that there was something very substantial going to go on in the energy space, because everything that you looked at suggested that the world could not keep going the way that it was going. In 2003, people were rioting in Bolivia not to sell natural gas to the US, there were these big energy issues. The developed world had ageing infrastructure, which became very clear, because there was a black out in the US, the big northeast blackout, and a blackout in Europe. I am sitting there and at the same time seeing that the technological solutions were not that hard, or at least they were coming down the tracks, so biotechnology, nanotechnology, really cheap information technology, which enables the new energy technologies in many cases to exist. I have also got huge faith in not just technology, but in engineers to drive down the cost of technology. So, if something vaguely works in 2012, it will work really well in 2013, and the year after it will be really cheap. We have seen that time and again. So, on the one hand you see all these problems and on the other hand you see solutions. The other driver being that there is 1.3 billion people still today without access to electricity and billions who do not have access to clean water or


IAA: What upcoming technologies should the industry lookout for in the coming years in the renewables sector? ML: I do not know whether taking current technologies and working them to their ultimate potential counts as new technology or not. Whilst there can be breakthrough new technologies, I know that this industry will transform the world economy, not just the economy, but in the social sphere too. Where we are now is clean energy starting to be cost competitive, so wind at seven cents, is competitive with coal, and competitive with natural gas. If you see solar panels on the rooftop, it is competitive with retail prices in the sunniest countries with high electricity prices. It is the beginning of, what I call, islands of competitiveness, quite big islands of competitiveness. If you go through to 2020, solar will be 50 percent of the cost it is now, wind will be 25 percent cheaper, LED lighting will be 90 percent cheaper than it is today, electrical vehicle batteries will be 50 to 75 percent cheaper than they are today, geothermal will be cheaper, mini hydro will be cheaper. The ability to integrate all of these technologies into the grid will also be cheaper, and meanwhile on the fossil fuels side, most likely things will be more expensive than they are in the present day. So that is what I see as happening. People are always very interested in new technologies, will it be marine energy, will it be wave energy. I do not think it will be wave, as there may be some of it in use, but I do not think it will be the transformatory technology. The technology that is going to transform the global balance towards clean energy is smart grids, plus cost reductions in all of the above, and dramatic improvements in energy efficiency. Maybe also some breakthroughs in solar, because the most efficient cells are in the low 40 percents in the lab, the theoretical limit is in the 70 percents, and the current production limit is 22 percent, so there could be some breakthroughs in solar. In batteries, there could also be some breakthroughs. In bioenergy there could also be breakthroughs. It could be that by 2020 more than two, three, or even five percent of aircraft fuels coming from bioenergy. IAA: What major factor, in the renewables sector, impedes cost reduction the most? ML: That is a very good question, because it is sort of like an ecosystem, you could say scale, but in order to achieve scale you have to break

down some barriers. You could then say the most important thing is to break down the barriers, but breaking the barriers alone is not enough. It is the barriers plus the scale, so it is just maturity of the industry. IAA: What would be the single biggest factor holding clean energy adoption back? ML: In the short term the biggest cloud in the sky is the European financial crisis. Europe was the leading region for clean energy. Europe is under tremendous dept and so it is hard to see much in way of new policy, new commitments. It even has an impact on the carbon price, as we are still now, in 2011, below the economic level of activity in 2008 and so carbon prices at 10 euros, which also feeds around the world via the CDM mechanism, because that was one of the mechanisms for financing projects around the world. The crisis in Europe makes it hard for Europe to throw its weight around and spend money. As a vibrant economy then we would be able to bring in more carbon credits from Asia at higher prices and so that would benefit smaller Asian developers and so on. I think that is the biggest short term hold back. ENQUIRY NO. 1202

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heating or cooking. That again is another huge driver that is forcing us to roll out these technologies.

Feb/Mar 2012 | industrial automation asia  35


process control

Properly sizing motors for a given load results in driving loads more efficiently and saving money. By Randy Barnett, director, electrical program delivery, National Technology Transfer

Determining Load Horsepower, Wiring, And Breaker Size For

Safe And Efficient Installations

‘L

et us just oversize the motor and we can run it lightly loaded — that will save us some money and be easier on the motor.’ This is a false belief among some who select and install motors. Properly sizing motors for a given load results in driving loads more efficiently, saving energy, and saving dollars. Motors typically are most ef ficient when they are 90 percent to 95 percent loaded. Just because a motor says 25 Hp on the nameplate does not mean the motor is producing 25 horsepower as it operates. The motor may be producing quite a bit less depending on the load requirements. If the motor constantly runs at these reduced horsepower requirements money is being wasted and you should 36  industrial automation asia | Feb/Mar 2012

consider replacing it with a correctly sized motor. A d d i t i o n a l l y, s i z i n g o f conductors and the fuses or circuit breaker supplying that motor are based upon the full load current rating of the motor, how often it is expected to operate, and other factors. Installing larger conductors and breakers than needed is a wasted expense. It is also important to realise that even at low horsepower requirements a motor still draws a relatively large amount of current. For example, a motor operating under no load at all still draws about 50 percent of its rated current. When You Replace A Motor, Match The Motor To The Job When replacing motors it is important to match the motor to

the job. In addition to selecting the proper voltage, phase (three phase or single phase), design letter, and code letter, be sure to select the proper horsepower rating. If the motor has been replaced previously, or is running a pump, fan, or other equipment that was not sized as part of an entire system by the OEM, you may not be selecting the right size motor. Taking some basic voltage and current readings to estimate your own horsepower requirements will provide you with a more efficient system. Such information is valuable when conducting an energy study. If the motor load varies 90 percent or less from full load for extensive amounts of time, the application may be right for a variable speed drive and, as such, significant


Determining Actual Motor Horsepower Motor running current and voltage values should be measured and recorded on a routine basis as part of a preventive maintenance program. The actual horsepower produced by a motor should be closely estimated in the field, as well. Energy losses, inefficiencies created by oversizing motors, or maintenance issues created by under-sizing motors are all good reasons to know how much horsepower the motor is attempting to produce. The quickest method to closely estimate motor horsepower is to use a digital clamp meter to measure current and voltage to the motor, and then perform a simple calculation. (See box: Use This Formula To Estimate Motor Horsepower). Be sure to follow the safe work practices appropriate to

the specific application. With the availability of remote display digital multimeters workers can reduce their exposure to lethal voltages and the arc-flash hazard zone. It is important to use a truerms clamp meter to get accurate readings. While motor currents can usually be read directly off the face of an adjustable speed

drive supplying an associated motor, other equipment will require the use of a meter providing accurate readings in the presence of harmonics and sine-wave distortion. Measuring Loads Other Than Motors You also need to record operating

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savings. For instance, if motor horsepower requirements can be reduced with a variable speed drive to decrease motor speed to 90 percent of the motor’s full rated speed, then energy consumption is reduced to 73 percent of what is required for full-speed operation. Just another reason to know the load requirements of your equipment. In some cases the motor may be overloaded, drawing more than its rated current. Whether it is bad bearings, a misaligned shaft or other maintenance issues, or just excessive load on the motor, one detrimental effect is occurring for sure: excessive heat is being produced in the windings. Heat deteriorates insulation and is the leading cause of motor failure. While properly sized and installed overloads will trip the motor at typically 115 percent to 125 percent of the full load current value on the nameplate, the heat developed during this time is sure to shorten motor life.

Feb/Mar 2012 | industrial automation asia  37


process control

Run a Fluke iFlex Flexible Current Probe around a single conductor. Or, you can centre the jaws of a clamp meter around a single conductor.

values of loads other than motors. Since horsepower is not determined for loads other than motors, simply use the procedure outlined in the box ‘Use This Formula To Estimate Motor Horsepower’ to measure and record the current value to the load. Examples of such loads might be hermetic refrigerant motor-compressors found in HVAC equipment, lighting loads, and heating elements. Rated-load current on hermetic refrigerant compressors and current ratings on other types of equipment need to be compared to measured values when you are dealing with breaker trips or overheating of equipment. To determine the size of breaker and conductors needed to supply your load, refer to the National Electrical Code (NEC), manufacturer’s instructions, drawings, and any local code requirements. Though the NEC has specific rules for various types of equipment, such as motors and HVAC equipment, generally conductors and circuit breakers are sized at 125 percent of the continuous load plus 100 percent of the non-continuous load. A ‘continuous load’ is one where the maximum current is expected to continue for three hours or more. One important point: when sizing conductors and breakers for motors use the appropriate table in the NEC for 38  industrial automation asia | Feb/Mar 2012

motor full-load amperage — not the value previously measured or motor nameplate information. The value previously measured is for helping to determine the size of the load. Sizing wires and breakers to supply a motor is based on code tables providing the fullload current values for specific phase, voltage, and horsepower motors. Manufacturer’s ratings and measured values are used for other than motor loads. For example, a three-phase, 25 horsepower chilled water pump motor is expected to operate at full load for three hours or more. The NEC tables indicate that the full load current of a three-phase, 460 volt, 25 horsepower motor is 34 amps. Therefore, the conductors supplying the motor must be sized at 34 x 1.25 = 43A (125 percent of 34 amps). Ampacity tables in the NEC are used to determine the actual conductor size based on insulation type, ambient temperatures, and other conditions. The maximum circuit breaker or fuse size for the motor is based on another NEC table, Table 430.52. The maximum value of this overcurrent protective device may range anywhere from 175 percent to 250 percent of the full load current. Always consult the NEC or a qualified electrician for exact sizes for motor wiring, fuses, and circuit breakers, as well as the overload protection requirements for motors. The same holds true for hermetic refrigerant motorcompressors and other types of electrical equipment. The Goal: A Properly Sized And Safe Installation Operating At Maximum Efficiency You must determine motor horsepower in the field to verify that the right-sized motor has been applied. If the motor is oversized, consider replacing the motor or installing a variable-speed

drive. Routinely measuring and recording current and voltage values is also an important part of a quality preventive maintenance program. Size the wiring and breakers for any type of load using the NEC. Remember, the goal is a properly sized and safe installation operating at maximum efficiency. ENQUIRY NO. 1301

Use This Formula To Estimate Motor Horsepower Horsepower (hp) = Voltage x Amperage x % EFF x power factor x 1.73/746 Where: • Voltage is the average of the three voltages measured: (A-B + A-C + B-C)/3 • Amperage is the average current of the three phase measured: (A+B+C)/3 • % EFF is motor efficiency per motor nameplate • Power factor is the ratio of true power (kW) to apparent power (kVA). In the absence of power factor measurement tools, a rule of thumb is to estimate power factor at 0.85 • 1.73 is a constant used when calculating three-phase power • 746 is the constant for converting watts to horsepower (746 watts = 1 Hp) Example: How much horsepower is a 25 hp motor producing at 472 volts and drawing an average of 20 amps per phase with a motor nameplate marking of 90 percent efficiency? Horsepower (hp) = Voltage x Amperage x % EFF x power factor x 1.73/746 = 472V x 20A x 0.90 x 0.85 x 1.73/746 = 17 Hp ENQUIRY NO. 1302


ENQUIRY NO. 375


Wireless Meeting Your Needs

Old and new plants are now starting to make more measurements in order to automate manual tasks, monitor critical assets, and improve productivity. These additional measurements can increase output and reduce operation costs. Wireless is increasingly the solution of choice for deploying these additional transmitters. By Jonas Berge, director, Emerson Process Management

N

AMUR is an organisation comprised of many automation end-users who jointly develop recommendations and best practices for process applications used in plants the world over. Recommendation NE124 covers user requirements for wireless in process applications including communication requirements for availability, coexistence and interoperability, security, power, integration into systems, forward and backward compatibility, network management, diagnostics, configuration and commissioning, device replacement, and certification. Application Classes The NAMUR NE 124 recommendation identifies three classes of applications. Wireless is predominantly used in class C applications (indication and monitoring), but also in class B applications (process control). Availability And Reliability A plant is a challenging environment for wireless since Radio Frequency (RF) waves do not propagate through metal such as vessels, piping, and structural steel. Below the pipe racks the range can be 50 m or less. Furthermore, daily plant activity, such as: moving vehicles, motors, starting and stopping,

40  industrial automation asia | Feb/Mar 2012

raising scaffolding, and welding, constantly changes the RF environment. Disruption of the wireless communication would mean the plant falls back to its productivity level before wireless was ever introduced. Therefore, sites must use a wireless technology with high reliability and availability. WirelessHART is a self-organising mesh network, supporting a full multi-hop, multi-path topology. For instance, the process variable from a remote transmitter is relayed from one transmitter to the next, in seven hops, around impenetrable obstacles or RF obstructions, until it reaches the gateway. Multiple paths are maintained such that when a new obstacle appears blocking the path, an alternate Application Class

Description

Remarks

A

Functional safety

Time-critical applications governed by the requirements of functional safety standards.

B

Process control

Time-critical, deterministic applications requiring high availability and reliability.

C

Indication and monitoring

Applications which are not time-critical.

Table 1 NAMUR NE 124 application classes

Sachin Ghodke, Mumbai, Maharashtra, India

software & Networks


path is used for the process variable to reach the gateway. All transmitters, regardless of manufacturer, participate in the mesh topology to ensure reliability needs are met. Redundant WirelessHART gateways are available if required. Thanks to the full multi-hop, multi-path mesh topology, a high level of productivity can be sustained. Other topologies such as ‘star’ cannot achieve the same result. Real-Time Performance Some applications require faster updates and lower latency than others. If the update period is configured too slow, alarms may not trigger in time, and the resolution of historical trending may not be sufficient for diagnosing process problems. If update periods are configured faster than required, technicians will have to replace batteries unnecessarily often. Therefore, use a wireless technology where the update period can be configured per measurement. Automatic retries of communication to increase the reliability should occur within the specified update period. Use a gateway that keeps track of latency for each wireless transmitter such that it can be verified from wireless network management software.

Security Wireless signals reach beyond the plant boundary. Outsiders must not be able to join the network, eavesdrop, modify, delay, or send data, and soon. If security was breached, production and inventory data could be revealed, or safety compromised. Therefore wireless communication in any application requires encryption, authentication, and other security measures. A remote site that deploys a Wi-Fi backhaul network should also consider the security of the backhaul network. The technologies security measures include encryption, authentication, verification, key rotation, and sequence numbers. Most importantly, security cannot be turned off; it is always on. Commissioning a wireless transmitter includes assigning a secret join key (password) which should not be done wirelessly. All WirelessHART transmitters have a wired HART maintenance terminal where the handheld field communicator or laptop interface that all plants already have can be connected to securely commission the transmitters before any wireless communication commences. As such the technology makes it easier to maintain security. Wireless transmitters based

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Feb/Mar 2012 | industrial automation asia  41


software & Networks

on other technologies cannot provide a comparable result because security can be turned off, and they use wireless or non-standard interfaces instead of the standard HART maintenance terminal. Also, the technology does not use IP addressing in devices. Coexistence The wireless field network has to operate at the same time as many other wireless network technologies in the same 2.4 GHz band such as Wi-Fi, Bluetooth, and ZigBee, and such. Therefore, use a wireless technology which supports coexistence with other wireless technologies. WirelessHART uses the IEEE 802.15.4 standard radio which uses Direct Sequence Spread Spectrum (DSSS) modulation enabling coexistence with other wireless networks. Additionally, the technology uses channel hopping as well as channel black listing, further improving its ability to coexist with other radios. A common application is to use it for the transmitters in a remote application such as a tank farm or wellhead, together with Wi-Fi for the backhaul of the data gathered, to a central location. Interoperability And Interchangeability Process applications require many types of measurements such as flow, level, valve position, pH, conductivity, vibration, temperature, pressure, and acoustic as well as on/off contact input and level switches. These measurements may come from different transmitter manufacturers. If communication with a broad range of transmitter types is not available, applications cannot be solved, and plant productivity could not be improved. Therefore, use an open wireless standard enabling a single common wireless infrastructure, without different types of gateways, device drivers, and configuration software for each type of wireless transmitter. The wireless standard must also include common security measures. If a remote mounted antenna is required for the application, use a gateway with a standard coax connector. The technology is based on a single common application protocol which all of its devices use. As such, all the transmitters which us the technology, of many different types from many manufacturers, integrate into the system the exact

Figure 1: All WirelessHART transmitters have standard (‘COMM’) terminals for connecting a handheld field communicator and other tools

42  industrial automation asia | Feb/Mar 2012

Figure 2: Power module prevents mixing of cells and enable hazardous area replacement

same way using the same application protocol. This makes it easy to solve diverse application needs using WirelessHART. Transparent System Integration Plants already have digital devices using hardwiring and bus integrated in intelligent device management software, predominantly using Device Description (DD) or the newer enhanced Electronic Device Description Language (EDDL) device integration technology. Using another technology and establishing new practices would increase the cost of adoption. Therefore, use a wireless technology that supports the EDDL standard, such that a single common system software application supports configuration and diagnostics for wireless transmitters from multiple vendors as well as the wired system in place today. Version And Lifecycle Management A control system has an expected lifespan of 15 years or more. Over its lifecycle, new types and versions of wireless transmitters will come into the plant. The control system must be kept up to date with these, to avoid obsolescence. Therefore, use a device integration technology which has no dependency on your version of Microsoft Window, as such, ensuring backwards and forwards compatibility between system and wireless transmitters. The EDDL technology is a text-based standard totally independent of Microsoft Windows. Thus the new versions of the technologies transmitters can be deployed without having to upgrade the Windows version on the control system. Battery Replacing batteries requires manpower, and inserting old and new battery cells together in a transmitter, or using a battery which has been dropped, could result in a hazard. A preferred wireless technology enables battery life of several years. Battery cells which are permanently encapsulated into modules prevent mixing discharged cells with good cells. Use battery modules which are intrinsically safe to enable replacement in hazardous areas, such that the transmitter does not need to be moved to a safe area for battery replacement. Make sure to use transmitters where the configuration is not lost while the battery is replaced. The technology uses the low-power IEEE 802.15.4


radio signal. Sensors are turned off between measurements. As such, the technology’s transmitters in a mesh topology enable a battery life of up to ten years depending on sensor type and update period.

Products And Software Some applications can not be solved using equipment from only a single vendor; from multiple devices, gateways, interfaces, system, configuration, troubleshooting and historians, it is probable that multiple vendors will be required. Therefore, use a wireless technology with broad support from many manufacturers. This should include a gateway with OPC, Modbus, and Ethernet connectivity into any third-party control system; and not just process variable into the Distributed Control System (DCS) but full transmitter setup and diagnostics information to the intelligent device management software. Wireless adapters for 4-20 mA/HART devices shall also be available in order to transmit smart device information into intelligent device management systems for legacy DCS that do not support digital HART communication. 4-20 mA and on/off signal input converters, should also be available. Use rugged, industrial grade, field mounted components, suitable for hazardous areas. The WirelessHART standard has broad support from more than a dozen manufacturers of process instrumentation providing a wide selection of transmitters, adapters, and gateways, that use the technology. The HART-UDP protocol over Ethernet from the gateway ensures full access to the technologies transmitter configuration and diagnostics. As such, complete and robust applications can easily be achieved using WirelessHART. ENQUIRY NO. 1401

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Wireless Network Management Preventing network disruptions and effective troubleshooting are key for an easy to manage network. Therefore, use a wireless technology which provides standard communication status such as signal strength and number of neighbours from all transmitters in the network, regardless of manufacturer. Use a gateway that tracks communication statistics such as missed updates, discarded updates, reliability, path stability, signal strength, latency, number of rejoins, and timestamp for last join, as well as maintains a ‘live list’ with node state, and if service is denied due to network load. Also use network management software which continuously monitors network health and battery status, and displays it graphically for an easy overview of problem locations.

Feb/Mar 2012 | industrial automation asia  43 iaa-80x240.indd 1

19/01/2012 17:24:20


software & Networks

Pushing Ahead

With Wireless

As Europe and the US battle their economic woes, the Chinese economy is booming. The largest employer in China, with an estimated staff of one million, PetroChina, is pushing ahead with improvements in efficiency, security, and safety. By Mark Johnston

A

t the invitation of Honeywell and with the permission of PetroChina, IAA visited the PetroChina Northwest Sales Centre Xigu Oil Tank Farm. The tank farm has been in operation for 50 years, meeting the demands of a growing industry. After years of separate systems and convoluted and inefficient control mechanisms, the company decided to modernise. A modern intelligent control system was implemented acoss the plant, where mobility is key, and a great time saver. The Petrochemical giant decided to implemented Honeywell’s OneWireless solution across their plant, installed by Honeywell Process Solutions, a division of the company’s Automation and Control Solutions business. Understanding The Problem The problem with the existing system used by PetroChina was the separation of systems involved in the operation of the plant, all operating in their own world, with no communication with one another.

44  industrial automation asia | Feb/Mar 2012

This caused great inefficiency and required added manpower, which has been greatly reduced with the new system. The objective of a new system to replace the existing one was to remove this inefficiency and reduce manpower required on-site, decreasing cost, and increasing safety. Not just in reduced manpower, but in also decreasing cost of wiring and maintenance, together with a unified monitoring system, which oversees the running of the plant. The requirement therefore was to interconnect all the existing systems together, allowing the terminal to run more efficiently. The company employed the ‘Experion Process Knowledge System’, from Honeywell, as its integration platform, while using PLCs and card reader systems already in place and connected them to a new automation system. Additional visibility provided to the operator and the plant planner were installed, namely the company’s Digital Video Manager and Business Flex KPI.


Implementation The OneWireless network ultimately allows field devices to coexist with Wi–Fi enabled devices, including laptops, cameras, communication equipment, and other devices, to exist on a common platform. The new wireless network consisted of five OneWireless multinodes connecting 22 wireless pressure transmitters that were installed near the pump station, and six valve position sensors to the Expersion system. Mobile stations are also now being used by staff at the plant, allowing greater efficiency enabling them to enter real-time data, which may include the arrival of containers coming from the railroad, and a description of their contents. Batteries for the new instruments are estimated to last between three to five years, and the implementation is expected to greatly reduce maintenance cost and commissioning time. The new sensors send back updated data every five seconds to a central control room, where the plant is monitored by staff.

Honeywell is a strong advocate of the ISA100.11a protocol, which operates in the 2.4GHz band. The protocol is a competing standard to WirelessHART, though Honeywell believes the ISA100.11a standard to be more comprehensive then WirelessHART, and considers it a more user-driven standard in terms of its development. The standard incorporates control as well as monitoring, which makes this protocol particularly useful for its chosen application domain. The control attribute, included in the standard, is made possible though its quick-update multinode topology. Another feature is its ability to tunnel, which allows the the protocol to encapsulate a different ‘payload protocol’ over a network, these payload protocols could be an existing protocol, such as, Hart, Profibus, etc. The tunnelling feature makes any transition to wireless easier and more accommodating to existing protocols. ENQUIRY NO. 1402

Case Study:

Honeywell Aids Woongjin Polysilicon In Operational Efficiency Woongjin Polysilicon manufactures polysilicon, which is the base material for solar batteries. Construction at the South Korea plant began in 2008 and had a goal of a two-year start date in order to maintain its assertive jump on the competition. The company successfully began production in September 2010, located in Sangju city of Gyeongsangbuk-do Province, the plant now produces eleven-nine level (purity level 99.99999999 percent) silicon. The company had to find a technology partner who could not only provide the proven experience and technology needed, but could also meet its aggressive time frame for start up. Woongjin preferred Honeywell over other suppliers for its unique technology approach and the engineering team’s experience and

confidence in meeting the plants’ difficult requirements. Honeywell provided systems that included Experion Process Knowledge System (EPKS) control stations and systems, safety systems and an integrated Closed Circuit Television (CCTV) and wireless mobile stations among other products. The Challenge The major challenge that the Woongjin Polysilicon company faced was getting its plant up and running in a very short time frame. In order to accomplish that goal the company needed to work with a proven technology leader in next-generation control solutions, but also one that would work handin-hand to accelerate the decisionmaking process and reduce project engineering time if possible.

In addition, Woongjin also had to find a partner that was versed in Foundation Fieldbus, since the company was forging a new path with the largest Fieldbus project in South Korea. “We had quite a few challenges to get our systems up and running in time but knew if we found the right partner that could demonstrate leadership and expertise in the areas we needed we could reduce

Feb/Mar 2012 | industrial automation asia  45


software & Networks

the installation and commissioning time significantly and help meet our deadline,” said JooTaek Lim, electrical and instrument team leader, Woongjin Polysilicon. The Solution Woongjin selected to work with Honeywell as their technology partner to help establish the polysilicon plant. Honeywell proposed a variety of solutions that were well advanced and stable to help address all the startup and commissioning needs. “Honeywell’s approach was really different from other suppliers we talked with and its engineering team was well prepared to tackle our difficult challenges,”

said Mr Lim. He continued: “We were ver y impressed by the project team’s performance and innovative thinking when it came to the benefits of advanced control systems.” The Honeywell solution offering included the following: • Three Experion PKS R311 System • Eleven EPKS Console Stations • Two Safety Managers • One Process Historian Document (PHD) • Sixteen C300 Controllers with Series C-I/O • Ninety-five Foundation Fieldbus Interface Modules • One hundred sixty-five Fieldbus Temperature Multiplexers • One FDM Server • One Digital Video Manager (DVM) Server with 16 CCTV cameras • Thirteen Wireless Mobile Stations • Six Large Wall Screens for graphic and CCTV monitoring

Conversation With

Honeywell’s OneWireless Head

IAA spoke with Soroush Amidi, Honeywell’s Global OneWireless Head, in Beijing, China, on the Honeywell’s OneWireless initiative. Mr Amidi is based in Montreal, Canada. IAA: What is your vision for OneWireless? Soroush Amidi (SA): What we believe is that the plant of the future will be all connected, amounting to a level of connection that goes beyond just the field instrument. We see connectivity between the people within the plant, connectivity with the process control network, and connectivity with safety systems. ‘One’ unified wireless network for the whole plant. 46  industrial automation asia | Feb/Mar 2012

Instead of installing field operator stations, Honeywell recommended its OneWireless mobile station solution. Operators were able to monitor process operations anywhere in the work environment allowing Woongjin to save installations and maintenance costs of an installed field station and improve the flexibility and efficiency of its operators. One of the unique technology approaches that Honeywell suggested was the integration of CCTV with a DVM solution. Now, the CCTV along with the field sensors connected to the control systems easily transfer alarms to the EPKS system which can help trigger pre-defined actions. “Honeywell was the only supplier who recommended integrating CCTV solutions with our wireless mobile stations — enabling us to take full advantage of these two technologies,” said Mr Lim. ENQUIRY NO. 1403

IAA: What is the technology that enables OneWireless, and its advantages? SA: For OneWireless, its main focus of operation is to enable a more unified system that operates seamlessly. Something that is important to mention is that the network has this concept of a ‘multinode’, which has the capability to simultaneously route data between Wi-Fi (IEEE 802.11 b/g) clients, ISA100.11a Field Instr uments and Ethernet/IP devices and host applications. As I said, the multinode offers w i re l e s s c o v e r a g e for ISA100.11a field instruments and Wi-Fi (IEEE 802.11 b/g) clients


IAA: What is the attraction of the ISA100.11a standard for process control applications? S A : T h e s t a n d a rd w a s d e v e l o p e d b y t h e International Society of Automation (ISA) and Honeywell believes it to be a more comprehensive standard than that of its main competitor, WirelessHART. Also, the ISA100.11a standard has been largely user-driven in terms of the standards development, incorporating many user ideas into its specification. The ISA100.11a standard has a fast update rate enabling the standard to be used in control applications as well as those of monitoring. The standard also permits tunnelling, permitting the ISA100.11a protocol to encapsulate a different payload protocol, in a sense, enabling these payload protocols to transverse the ISA100.11a wireless network possible. Making the process of implementing such a network easier to manage. The company already has many devices that conform to the ISA100.11a standard, including pressure, temperature, level, and vibration monitors, to name a few. As the standard has not yet been fully ratified by the IEC, we will aid our early adopters, of the standard, with the assurance

that we will upgrade their devices, via a firmware upgrade, to the standards final version, when available. IAA: Where is OneWireless being implemented in the industry? SA: The range is broad, in terms of where our networks are being rolled out. Ultimately they range from small implementations of just a few field instruments to large, plant-wide, implementations utilising all aspects of our OneWireless methodology. In the case of our PetroChina implementation, we have implemented our OneWireless network across a single site, while PetroChina evaluates its suitability for company wide roll out. This is considered normal procedure and in PetroChina’s case was driven by a need to unify its networks and modernise its infrastructure. Another issue is portability and convenience of diagnosing equipment, as the network allows portable monitors with updates to a central control room. The capability of maintaining equipment is greatly increased, allowing real-time diagnostics and remedy. This method saves, not just on money, but also in time management, as efficiency is greatly increased. ENQUIRY NO. 1404

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such as Handhelds. Also, the multinode has this feature that allows the device to auto-discover other neighbouring multinodes enabling a much larger multi-application meshing Wireless Local Area Network (WLAN). This, in essense, is our OneWireless network, a multi-application, expandable, flexible wireless network, suitable for monitoring and control in an industrial plant. Inside the protective casing of the multinode are two IEEE 802.11a/b/g radios and one IEEE 802.15.4 radio for ISA100.11s field instruments. The purpose of the two IEEE 802.11 a/b/g radios being on the one hand to join together nearby multinodes forming a larger network, with the second IEEE 802.11 a/b/g radio used as a Wi-Fi access point. The third radio of the multinode, IEEE 802.15.4, is used in conjunction with the ISA100.11a wireless field instruments and the host application to route data between ISA100.11a compliant devices. There are a number of advantages to this method, namely a reduction of maintenance costs from implementing a single network infrastructure, rather than maintaining multiple networks, a reduction in the total life cost, and a redundancy advantage with each being interconnected to many other multinodes, giving many paths to send data, so if one path fails there will always be another to maintain an open connection.

Feb/Mar 2012 | industrial automation asia  47


instrumentation & Measurement

Points to consider when selecting the right automation system for the right production environment. By Didier Lacroix, senior VP, international sales & services, Cognex

Vision Systems:

Meeting The Need A

s international markets take cautious steps towards 2012, many businesses in Asia are also expecting a more challenging year ahead. This is especially true for those that depend on the strength and purchasing power of Western export markets. While lower profit margins in a slowerpaced business climate may be cause for concern, it could however, also be a fitting time to rethink, retool and revamp. The Human Element Companies that are currently relying on human vision to perform Quality Control (QC) inspections on the production line should consider adopting machine vision. 48  industrial automation asia | Feb/Mar 2012

Since the outcomes of manual inspections can be subjective depending on the experience and alertness of the human operator, such a QC system is unlikely to be a foolproof solution. While this may be acceptable in certain industries, businesses in highly regulated sectors such as pharmaceuticals and Food & Beverage (F&B) may find it less-than-satisfactory. Similarly, high-tech industries such as semiconductors and electronics manufacturing, and automobile assembly lines may also require a more reliable means of QC beyond the manual approach. Besides quality assurance, machine vision can also play a

major role in part and product traceability from cradle to grave. Given the advantages that have been granted by barcode technology (1D, 2D), manual recording and part tracking have become a thing of the past. However, choosing a robust system that is capable of performing to unique business requirements, and industry and regulatory standards — in the sea of vision products and technology suppliers that are currently available on the market — can be challenging. It is therefore useful for the buyer to carefully consider certain issues in the decisionmaking process for choosing a suitable vision system.


Working Out The Tools Although certain vision applications are complex, many others may be addressed with an affordable, standalone solution. The advantage of such a system is that it does not need to have a Personal Computer (PC), either for configuration or in production. The system should provide plug-and-go performance that allows quick configuration of the application, from beginning to end,

straight out of the packaging. The system should not require a PC to be installed each time changes need to be made to the application. A true standalone vision system should also allow connection to a monitor to display live images — all without a PC. The need to share data, support decision-making, and

enable highly-efficient integrated processes makes networking an important mechanism in vision applications. For example, networking enables vision systems to transmit pass/fail results to PCs for further analysis. It also facilitates direct communication with factory automation devices in an integrated process control system.

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The Machine Advantage Certain industrial environments require a vision system that can read 2D Data Matrix codes that are degraded or poorly marked. In other situations, it may be necessary to read barcodes that vary in position. For example, a manufacturer of canned milk powder would need a system that can read barcodes on cans which show up on the production line at various angles and orientations. The vision system should have the flexibility to read codes that are printed on various material surfaces such as metal, glass, ceramic, and plastic. It should also be able to accept the type of part marking method used, for example, dot peen, etching, hot stamping, and inkjet. Depending on the speed at which the production line operates at and the throughput requirements, a high-speed reader may be required to carry out a successful read operation. Some of the fastest vision systems on the market can read more than 7,200 codes per minute. The ability of the vision system to increase capacity is also another consideration that should not be left as an afterthought. Besides being able to perform high-speed inspections and identify errors at an accuracy rate of 100 percent, the vision system also needs to be scalable to handle future rises in production volume.

Feb/Mar 2012 | industrial automation asia  49


instrumentation & Measurement

frequent wash down of equipment, the supplier should be able to offer external enclosures that have been pre-qualified for use with the system.

Machine vision decreases error and increases productivity.

In order to integrate a vision system with the Programmable Logic Controllers (PLCs) and other automation devices in the plant, the system must be able to support Industrial Ethernet protocols such as EtherNet/IP, PROFINET, MC Protocol and Modbus TCP. These protocols enable vision systems to be connected to other devices over a single Ethernet cable, eliminating the need for complex wiring schemes and costly network gateways. The software capabilities that come with the system also play a vital role in terms of managing v i sio n s y ste m s t h rou g hout the ma nufacturing proce ss. The software should provide centralised management to the user, allowing easy control and monitoring of all vision systems over the network from any location, on or off the plant floor. Choice Of Accessories A common mistake sometimes occurs when there is an overemphasis on evaluating the vision system at the expense of considering accessory products. It is important to note that making a wise choice in terms of accessories can make a difference towards successful system implementation and integration. This is especially true in the choice of lighting, which can make or break the application. 50  industrial automation asia | Feb/Mar 2012

In some cases, the intensity of the light may be too low, necessitating the installation of stronger lighting. In other cases, the ambient lighting on the production floor may be too intense, with the external glare causing a degradation in the quality of the images taken by the camera. In these scenarios, installing tinted plastic panels to filter off some of the light could be a cost and production effective solution. To allow the swift and easy connectiv ity between the vision system and other factory automation devices and networks, it is necessary to ensure that the vendor offers the required communications peripherals (eg: I/O modules and network gateway modules). A networked operator interface panel allows easy plug-and-go setup and deployment, in addition to ongoing monitoring and control of vision systems without a PC. During the selection process for an operator interface panel, it is advisable to choose one with an intuitive, touch-screen interface. Some vision systems may be assembled into rugged, IP and N E M A - rated meta l ca se s to withstand dust and moisture without requiring a separate enclosure accessory. However, if the operating environment is especially harsh or requires

Promises That Count A system’s performance is tied directly to the effectiveness of the vendor that supplies it. While a technology supplier may appear promising on the World Wide Web, buyers need to perform a further check to determine if the former has a strong local presence in terms of pre- and post-sale technical support. While a manufacturer may not necessarily have a local office at the buyer’s location, it may still be able to offer strong support via a representative systems integrator or distributor. It is important to be informed b e fo r e h a n d t h e f u l l r a n g e of support services that are available. Buyers should take note that the chosen vision supplier understands the business’ unique supp or t re qu i re me nt s. T he supplier should also be able to provide the customer with the required resources during each stage of the project, ie: from application development and systems integration, to deployment and beyond. One method of ‘testing out’ the efficiency and reliability of vendors is to request them to set up and run and a demonstration onsite. The speed at which each vendor arrives and readies the equipment is usually a reliable indicator of the level of service that they can provide during implementation and for the lifetime of the product. Last but not least, a good supplier does not just try to sell its product — it takes the time to understand and evaluate all of the client’s requirements before proposing a solution that meets their needs. ENQUIRY NO. 1501


ENQUIRY NO. 358


instrumentation & Measurement

Machine Vision:

Meeting Fast

Changing

Consumer Patterns

The fast changing consumer patterns of today are paving the way for greater use and implementation of machine vision to aid in the production process. By Maria Carlsson, product manager, vision sensors, Sick to quickly adjust or add quality inspection for a new product type in phase with changing consumer needs. To further increase the usability, the user interface can also be available off-line, as an emulated device. Then, it is possible to fine-tune the inspection configuration of an existing product type or simply add a configuration of a new one without disrupting ongoing production.

M

achine vision has the potential to be every man’s gear on the production floor, to help keep up with the demanding production rate and targets. However, to do that, it needs to be very user friendly and flexible enough for rapid adjustments; vision sensors with focus on ease-of-use are a response to this need. One may think that a vision sensor would be easy to design because it is so easy to use. However, to create a vision sensor that is user friendly, powerful, and flexible, clearly requires innovative skills. There are several components within a vision sensor that contribute to its ease-of-use. User Interface: The Base Of Usability The most obvious component is the user interface. A configuration interface with an intuitive workflow, simple tool icons and graphical feedback enable people, also without programming skills, to configure the device. A user-friendly interface makes it easy

52  industrial automation asia | Feb/Mar 2012

Image Quality: The Core Of Machine Vision The most fundamental component to ease-of-use, and machine vision itself, is good image quality. What, then, is good image quality? The straight answer is usually high resolution — or number of pixels per millimetre. This is however only part of the truth. The definition of a good image, when it comes to machine vision, is to secure a reliable and repeatable extraction of the details of interest in the image. This is ensured by using the right illumination and optics — this cannot be stressed too hard — to succeed with machine vision, make sure to use the proper illumination and optics. With all the pixels and processing power in the world, the application will fail if it is not possible to distinguish the important features in the image. Smart Algorithms: The Power Of Vision Sensors The third main component that contributes to ease-of-use hides in the inspection tools’ analysis algorithms and how these can be combined. A seemingly simple but powerful ‘locate and inspect’ concept is a means to reach powerful simplicity. After ‘teach-in’ of an object and configuration of the needed inspections, this concept lets the vision sensor, in run-time, first locate the objects on the production line, and then automatically perform the inspections relative to the found pose of the object. This makes it extremely easy for a user to configure an application. Moreover, it also overcomes need for expensive fixtures and complicated light switch trigger signal integration. The core algorithm for the ‘locate and inspect’ paradigm is an object locator tool. This tool needs


Vision Sensors As Powerful As Smart Cameras Complementing the flexible illumination concept and the smart algorithms, an easy-to-use calibration feature increases the power and usability of the vision sensor even further. After a simple onestep procedure, using a chess-patterned target, the vision sensor can report values in millimetres and

compensate for distorted images. Vision sensors are increasingly supporting the trend of distributed communication, enabling centralised control and result management. S t a n d a rd i s e d f i e l d b u s p ro t o c o l s a n d w e b technologies are moving into vision sensors, securing an easy handling even for communication and customised operator interface designs. The border between vision sensors and smart cameras is becoming increasingly vague; the advantage of the vision sensors in terms of solution cost and time saving due to ease of use, persists. Conclusion The above discussion has mainly touched upon the usability of solving production problems with vision sensors. Vision sensors with simple configuration interfaces, innovative illumination possibilities and smart algorithms are indeed paving the way for machine vision to become every man’s gear. Usability and powerful simplicity is the key to keep up with the rapidly changing consumption patterns — without compromising productivity. ENQUIRY NO. 1502

ENQUIRY NO. 359

to detect an object and accurately measure its pose regardless of variations in position, rotation, scale, tilt, illumination, reflections, and occlusion. The tool’s advanced matching algorithm furthermore needs to perform at a very high speed, and on the limited computational resources found in a small vision sensor. This calls for an optimised implementation, often on a purpose specific Digital Signal Processor (DSP) and sometimes even utilising the highly parallel computational abilities of a Field Programmable Gate Array (FPGA). The processing time of the algorithm should not only be low, it should also vary as little as possible for all kinds of images. This gives a deterministic response time of the vision sensor, making it easy to integrate into a real-time solution.

C  M  Y  K

Feb/Mar 2012 | industrial automation asia  53


energy

Lars Sundstrom, Lund, Skane, Sweden

With the right focus and enabling policies in place, global energy requirements can be largely met by the use of wind turbines. By Amreet Singh

Winds T

Of

he world’s energy needs have been growing continually as population rises and c o n s u m p t i o n re q u i re m e n t s increase. The current population stands at almost seven billion and is expected to grow up to 10 billion in 2050. This means that our global energy consumption will only keep increasing. Traditional energy means such as the burning of fossil fuels provides us with the bulk of our energy needs at the moment but this is doing more harm than good. Large quantities of carbon dioxide and other greenhouse gases are being released into the atmosphere and the effects of global warming is already being felt. Also, fossil fuels are a finite resource. Millions of years are needed in order to form coal, oil and natural gas and once they are used up, they cannot be replaced. Estimates vary but they may not last till the following century. This is a very real problem because we may end up facing an energy requirement that we cannot fulfill or an environmental problem that we cannot reverse. 54  industrial automation asia | Feb/Mar 2012

Change Either way, it is important that alternatives are looked into. A renewable and cleaner energy source that can fulfil our needs is needed. One such energy harnessing method is through the use of wind turbines. Wind turbines are considered a green energy-deriving source because it attains energy through wind, which is a naturally occurring renewable element. With wind technology gaining popularity, they are an industry segment that should be closely watched. Wind Turbine Trends & Developments Turbines are found in a variety of operations such as dams, nuclear plants and wind farms, and each of them has seen technological growth and development since its inception. In particular, the modern wind turbine has come a long way from its beginnings. Wind generation technology today sees annual worldwide growth by as much as 30 percent. Combined sales of large wind power plants and smaller turbines have also reached US$4

billion yearly. Examples of such technological growth can be seen in the rotors of wind turbines. The rotor is a part of the wind turbine that has undergone the greatest development in recent years. Early turbines from the 1980s had rotor lengths of 15 m, generating about 20 to 60 kW but current lengths can surpass 100 m and generate about 2 MW. Offshore turbine rotors can reach a greater length and generate even more electricity. The design of the rotors were initially taken and replicated from blades that were developed for aircrafts. These were not optimised for the stresses that the wind turbine blade had to take. Modern day rotors are being constructed out of aerofoils that have been specially designed for a wind turbine’s use. These aerofoils are designed with specificity in mind, where different materials are tried out to ensure they were strong and stiff enough, and have a high fatigue endurance limit. These rotors undergo research and testing methods such as proof, load and fatigue testing. Rotors are also tested in wind tunnels, which can provide wind speeds of up to 105 m/s. The blades are built out of glass fibre reinforced plastic. Other materials like laminated wood can also be used. Due to such vigorous testing methods and better quality materials, current rotors have an expected life span of at least 20 years. Other than the rotors, the drive train has also undergone developments. Presently, there are several drive trains one can consider. The first of which is the direct drive or otherwise known as the gearless drive train. Conventional wind turbines have blades that spin a shaft connected through a gearbox to the generator. In the gearbox, the multiple wheels and bearings suffer tremendous


Gear Construction Techniques Wind turbine manufacturing is undergoing developments due to the current focus on its green and renewable means of attaining energy. Manufacturing processes are under review as many components require heavy machining. Ideas from other manufacturing areas are being brought in to optimise wind turbine production. With production needs rising, it becomes imperative to reduce production time and as such technological advances have come about to cater to the need to be more efficient, faster and to produce better grade material. The focus put on gearbox construction is also a result of it being one of the most vulnerable components of the wind turbine. Gearbox failure will often result in the shutting down of the wind turbine until it is repaired and as such this equipment needs to be of the best quality possible. The Future Of Global Energy Supply Countries like India and China, who have been relying heavily on coal to fuel their energy needs, have already embarked on turbine technology and now

lead in the manufacturing of wind turbines. They represent the global direction of current energy acquisition focus. As much as 80 percent of the global energy supply could be met by renewables, such as wind or water, in 40 years, if technology development and focus is placed in the right direction, according

to the Intergovernmental Panel on Climate Change. This would also mean that savings of up to 250 gigatonnes or one-third of carbon dioxide and greenhouse gases could be achieved. As such, turbines play a vital role in the present and future of energy attainment. ENQUIRY NO. 1601

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stress due to wind turbulence and any small problem can manifest itself by bringing the entire turbine to a halt. However, direct drive systems do away with the gearbox completely. Instead, the rotor shaft is connected directly to the generator, which operates in tandem with the blades at the same speed. In the generator, magnets spinning around the coil produce the current. Due to the lack of gearbox, the direct drive system is seen as one that requires less maintenance and has become the preferred choice for offshore turbines.

Feb/Mar 2012 | industrial automation asia  55


Pavel Matousek, Czech Republic

sector spotlight

Robotics For

Electronics Manufacturing Electronics manufacturing is crucial to any modern-day economy, given the demand for technology and increasingly sophisticated gadgets. The use of industrial robots promises to take the sector to even greater heights. By Shahnawaz Abdul Hamid

T

he field of industrial automation is vast and diverse, having been implemented in almost any manufacturing sector imaginable. With industrial automation solutions, manufacturers have been able to increase production, improve quality and lower costs, in effect meeting the growing needs of the market. However, it is important to realise that it is not manufacturers who have chosen to implement automation in the manufacturing environment, but rather the everdemanding consumer in today’s market. Consumer preferences — for better products, more variety and more competitive pricing — have driven this need for automation. We can generally consider the following indicators

56  industrial automation asia | Feb/Mar 2012

to determine success or failure in the use of automation: consistency, reliability, accuracy, lowered costs and flexibility. In the realm of electronics manufacturing, industrial automation is able to provide a multitude of solutions in a wide range of operations, from assembly, to PCB laser drilling to data storage. Whatever the type of operation, automation allows for a high throughput, a crucial criterion of the electronics manufacturing industry. Within automation, man-made tasks are increasingly being made easier or being replaced through the use of robotics. Industrial robots were first adopted for use in the automotive industry, primarily for welding operations,

before the electronics industry began using them for assembly applications. These ‘intelligent’ machines are being used in many other sectors as well, given the speed and accuracy of their work. In 2007, it was reported that 118,000 new industrial robots were supplied worldwide. A Blossoming Sector If robotics has made the life of manufacturers easier than the same can be said of electronics with respect to the average consumer. Electronics allows us to enjoy much of today’s comforts, from the ubiquitous mobile phone to car navigation systems and personal computers. In the current high-technology era, electronics forms the bedrock of


The Cleanroom Nevertheless, it should be said that electronics manufacturing is not without its own set of challenges. Perhaps one of the biggest challenges the sector provides is its low tolerance for foreign particles during the manufacture and assembly of certain components. This makes the cleanroom, an environment that has a low level of pollutants such as dust, airborne microbes, aerosol particles and chemical vapours, an important cog of the electronics manufacturing process. These isolated environments are built to allow engineers to control humidity and temperature, within certain specified parameters. Typical cleanrooms provide laminar, vertical flow of filtered air in order to move particles to exit vents at the floor level.

Strict protocols which maintain cleanroom integrity reduce the risk of product damage and lower yields. These protocols also define procedures for operators on how to handle materials, including cleanroom attire and cleanroomcompatible equipment used. The stringent requirements of cleanrooms are rendered even more challenging when one considers the constant contributor of contamination, human operators. Despite the standard operating procedures available to maintain sterility, some level of contamination is unavoidable with human operators. Human beings give off body heat, carbon dioxide and moisture through respiration. This makes highly automated fabrication facilities desirable, given the removal

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manufacturing operations in many developed nations. In Singapore for instance, manufacturing output in the electronics sector reached S$63.9 billion (US$49.5 billion), contributing 30 percent to Singapore’s manufacturing ‘pie’ in 2009. As people around the world grow more affluent, the demand for electronic gadgets tends to increase. This in turn will make the use of automation, such as robotics, within the sector even more crucial to ensure that quality and quantity parameters are met. The use of ‘intelligent’ automation and robots in the sector also gives technopreneurs the flexibility to site some of their production processes in developing countries without a corresponding decrease in product quality. This helps in greatly reducing labour costs.

Feb/Mar 2012 | industrial automation asia  57


of human operators from the cleanroom area. Therefore, apart from helping to reduce costs, the use of industrial robotics in the cleanroom helps to improve product yield through cleanliness. This standard is especially needed in electronics manufacturing, given the strict quality control measures.

Joel-Lillaby, Sweden

Robot Applications Although the field of robotics is a diverse one, robot applications in cleanroom environments, for the manufacture of semiconductor devices for instance, are a narrower field. This niche sector uses robots mainly for the transport and handling of substrates between the numerous process steps. The earlier years of wafer production saw simpler robots a n d c o n t ro l l e r s , g i v e n t h e straightforward tool geometries and handling requirements. H o w e v e r, a s w a f e r s i z e s progressively reduced according to Moore’s Law, automation and robotic systems were required to similarly advance.

The use of industrial robots has made easier a multitude of manufacturing tasks.

58  industrial automation asia | Feb/Mar 2012

A s m e n t i o n e d e a r l i e r, cleanliness is an overriding concern in electronics manufacturing, requiring the elimination of contamination sources wherever possible. For example, up to 80 percent of yield loss in the production of high-volume, Very-Large-Scale Integrated (VLSI) circuits is attributed to random pattern defects, many caused by contaminating particles. These contaminants must be taken into consideration when designing robots for substrate handling. Generally, two situations are cause for concern. These are airborne molecular contamination from particles and outgassing generated by the robot and direct contamination when the substrate is in contact with the robot’s claw. As such, the best design practices incorporate the following measures: minimise the number of moving parts on the robot, place all moving parts below the substrate, enclose and seal the robot interior and evacuate generated particles, use of internal cabling, application of coating and treatment to robot surfaces, the use of stainless steel screws and washers, minimise contact surface of end-effectors (ie: robot claws), and direct-drive trains to eliminate belts and transmissions. Substrates in electronics manufacturing are typically handled in horizontal planes at different vertical positions and within reach of the average human arm, often in a cylindrical coordinate frame. As such, the Selective Compliance Arm For Robot Assembly (SCARA) is used, given its kinematic structure. The generic SCARA robot is modified when used for substrate handling. Its vertical axis is relocated from the end of a two-link arm to the robot centre, allowing it to reach into small openings to

Windell Oskay, US

sector spotlight

Wafer fabrication, a cornerstone of the semiconductor industry, has come a long way since its humble beginnings.

pick and assemble silicon wafers. This modification also adds to the ‘cleanliness’ of the robot, making it even more suited for use in the cleanroom. Advantages The SCARA-type kinematic structure has some advantages o v e r m o re c o m p l e x ro b o t manipulators: • Small footprint relative to the work envelope • Good vertical arm stiffness • Rugged against minor collisions • Short pick-and-place time • Good horizontal repeatability For FPD manufacturing, the robotic technology used is similar, though the robots are usually bigger to handle large glass substrates. The robots used can be as high as three metres and handle FPD cassettes between tools, as well as individual panels within a tool. In conclusion, the use of industrial robots in electronics manufacturing has helped to resolve many issues, specifically the improvement and maintenance of cleanroom standards. Given the sector’s drive for cleanliness to produce better yields or throughput, it comes as no surprise that ‘sterile’ robots will continue to drive the key performance indicators of fabrication plants. ENQUIRY NO. 1701


features

Safety As A Priority IAA spoke with Paul Gruhn of ICS Triplex, a company acquired by Rockwell Automation. Mr Gruhn is a safety expert and ISA fellow with many years experience in the oil and gas industry.

S

afety is a central endeavour f o r a n y i n d u s t r y w h e re dangers persist and complex processes run. It is not just a matter of writing detailed documentation on procedures and clear explanations on the correct operation of machinery. Those involved need to be mindful and as Mr Gruhn points out complacency is a greater cause of accidents than a lack of detailed safety manuals and/or procedures to stick to. IAA: What are the top considerations when assessing safety? Paul Gruhn: We perform what is known as a Process Hazards Analysis (PHA). Based on past incidents, we have learned the hard way. So, we as an industry developed a number of techniques on how to do a proper PHA to identify all the safety and operating problems that might exist inside a facility.

The regulations around the world changed, saying that detailed PHA had to be done before being allowed to build a facility. In order to satisfy these requirements it was necessary to have competent qualified people involved in these studies. This brings us to the problem of downsizing, as a lot of the right qualified people are not left in the facilities anymore, or they are too busy with their job that they do not have the time to do the required safety studies. Another problem is that the studies may be done, but not in a very comprehensive way. As such, leading to a greater risk of accidents, because it was thought it was just a tick, and the job is done. So, having enough competent people doing things right is probably the primary issue. Having the right people, and doing the right things according to the regulations that have resulted

in years of learning the hard way based on past innocents. A lot of people feel invincible, and feel this way because they have not had an accident in the past 15 years. They believe an accident is not going to happen and complacency sets in. We wrote the manuals from our years of combined knowledge and to insure accidents never occur or the risks are greatly reduced. IAA: What trends are you noticing in the industry? PG: Prior to 1968 most safety instrumented systems (also known as emergency shutdown systems) were implemented using relays. The advent of the Programmable Logic Controller (PLC) changed all that. Hard wired solid state systems — systems designed to replace relays without using software — were also popular for several decades. Software-based systems make up the majority of safety instrumented systems installed today. Feb/Mar 2012 | industrial automation asia  59


Safety in the oil and gas industry is crucial to its successful operation and the smooth sailing of energy markets.

General purpose PLCs have a variety of weaknesses in safety applications that have been recognised for many years, primarily the lack of thorough diagnostics. Standards, users, vendors and integrators have understood these weaknesses and some have engineered customised solutions to overcome many such weaknesses. Such a customised general purpose PLC engineered and configured for safety is referred to as a ‘safety configured PLC’. Specialised PLCs designed from the ground up specifically for critical safety applications are referred to as ‘safety PLCs’. Safety PLCs have been available since the early 1980’s, with more vendors entering the market over time. Changes in technology have led to a variety of recent developments, with many vendors releasing new systems that are a considerable departure from the past. Some of the latest trends in safety instrumented system designs in the process industries are smaller, scalable, distributed systems; flexible redundancy; integrated control and safety from one vendor; safety field busses; field device diagnostics and certifications; certifications for personnel; partial stroking 60  industrial automation asia | Feb/Mar 2012

of valves; and Safety Integrity Level (SIL) ratings for fire & gas systems. IAA: Can you describe your position and role within ISA 84 in more detail? PG: The charter for the ISA 84 committee was originally started in 1984 to create a standard for safety systems. However, it did not get much momentum until 1987. I have been a member of the committee for around 20 years, and we would typically meet two or three times a year at the ISA leader meeting. At the section level, for example, the Houston section, I was a member of the board and worked my way up to president, and ended up director of a couple of divisions. I was the founding director of the safety division within ISA. I have been teaching at ISA for 15 years, but before me there was someone else who taught the first version of the ISA safety system class. He taught it once, and had once seen me teach something similar elsewhere. He asked me to take over the class, so for the past 15 years I have been teaching the ISA course and developing the different course they have on safety systems.

IAA: You are also a member of the ISA 101 committee, what is your role here? PG: I have a keen interest in a number of different areas of study. One would be graphical design. What lead me to learn more about graphical design was a user experience problem with Human Machine Interface (HMI) units. As I visit a lot of facilities and trade shows, I see a lot of HMI’s and intuitively I know what I am looking at is a bad HMI, but I could not put my finger on it as to why. This lead me to read some books related to HMI and situational awareness. I was aware of the ISA 101 committee, which is now creating a standard on HMI’s. I contacted the ISA 101 committee and said that I would like to be a member. I read the draft of the new HMI standard and submitted suggestions of my own and comments I had and submitted a white paper I had wrote and they actually incorporated a number of my suggestions into the draft. I have been a member of the ISA 101 committee for about one and a half years now. I am minor participant, so there are people who are more active than me, though I have made suggestions and they have been incorporated.

J K, UK

features


I am more of an active long-term member of the 84 committee. IAA: You commercialised your own software, tell me about that and what motivated you? PG: About a year after joining the company in 1988 I took on a reliability and safety role. We used to have to do many calculations on our system performance, which although very simple algebraic calculations were tedious to perform. We were only modelling the logic systems, not the sensors and finite elements. I remember doing all the calculations by hand with a calculator and having graph paper and plotting out everything that needed to be included. It literally took me the whole day to do the calculations, and plot out on graph paper, to show an end user. I realised that I needed to learn excel spreadsheets and

automate the whole process. I developed spreadsheets for my own personal use when I was involved in the committee. On the 84 committee we had four task teams and one of them was the reliability and modelling group. We were the ones writing the documentation and instructing people how to do these calculations. People had learned about the spreadsheets, I had developed, to automate the calculations and people asked me for a copy. I realised then that what I had developed could be commercialised, as there appeared to be great demand for it. From this I developed a set of spreadsheets and begun selling them for US$95, which people then bought. I begun to realise that not everyone wants a spreadsheet or knows excel for that matter. I then begun to learn visual basic programming

a n d Wi n d o w s d e s i g n , a n d other related technologies and knowledge that would enable me to design and write a program that could be used all over the world, without needing a spreadsheet, or knowing excel. Designing and writing this software took me a number of years. But I knew people wanted it, and eventually they started buying it, around the world. In 2005, when I rejoined ICS Triplex, I shut down my consulting business and stopped selling the software, as I did not want any perceived conflicts of interest. There are at least four or five companies that now offer similar software, though I would like to think that I had the first one and that people now analyse and model systems based on software that I originally developed. ENQUIRY NO. 1801

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Feb/Mar 2012 | industrial automation asia  61


features

Industry Eye 2012 Executive Opinion

Q:

What major challenges do you foresee for your industry over the next 12 months, and how do you plan to overcome them?

Rajiv Ghatikar, VP and GM, Asean and Australasia, Siemens PLM Software The outlook for 2012 is certainly cautious, with the current global economic situation possibly impacting industry sentiment and affecting business decisions. As such, there will be the need for all PLM vendors to be more competitive, especially when customers will be more cautious in their spending and risk appetite. Apart from the challenges facing the PLM industry, some of the major challenges that will affect Asian manufacturers include: • Worldwide Competition — Intensive global and local competition increasingly forces manufacturers to produce quality products in the shortest possible time at minimum cost. The pressure to reduce lead times is particularly obvious and every country will continue to seek to upgrade the skills of their citizens. Therefore, competition is more intense at all levels. • Shorter Product Cycles — The primary force driving manufacturing is a reduced product development cycle. While continual changes in design are implemented, more frequent and additional Numerical Control (NC) programming is required to manufacture products, along with the dies, molds and tools that are often desired. • Newer Methodologies — Newer manufacturing methodologies are becoming popular. Digital manufacturing, collaboration, concurrent engineering, lean production, supply chain management, and design for manufacturing have moved manufacturing operations into the mainstream. • Manufacturing Complexity — The tools and

62  industrial automation asia | Feb/Mar 2012

processes used in manufacturing are also becoming more complex, to gain higher production efficiency. The rapid pace of technology change continues. Highspeed machining has gained acceptance to improve both product quality and productivity. Multi-functional machine tools such as machining centres, turning centres, mill turn machines, and multi-axis lathes are commonplace. More NC programming is driven by the continued change in technology and increased complexity in manufacturing tools and processes. Because of various recent calamities in Asia, particularly the natural disasters experienced in the Southeast Asian region, what manufacturers need now is to increase productivity to boost manufacturing to make up for lost time. In 2011, we released NX 8.0 with focus on CAE solutions; Tecnomatix 10.0 with enhancements to increase manufacturing productivity, and Teamcenter Mobility 2.0, which enables iPad connectivity to the enterprise Teamcenter backbone from any Wi-Fi or mobile broadband-available location. We also recently offered a 45-day free download of our Solid Edge CAD and FEMAP CAE software solutions, allowing prospective customers, at no obligation, to work with the real production software before they commit. We continue to have confidence, even in tough times, due to the increasing productivity benefits of our product portfolio.


The lackluster US economy and troubled Euro zones are major challenges for the exportdriven economies in Southeast Asia. These uncertainties in the market has led to much speculations and fluctuations. However, I see this as a good time for us to engage more intensely with our customers and partners, to relook into their processes and designs, to seek productivity improvements and higher energy efficiency. I believe a partnership built during difficult times is a partnership that lasts.

Tony Cosgrove, VP & GM, Honeywell Process Solutions Asia Pacific In Year 2011, as the impact of both the America’s debt crisis and the Eurozone crisis unfolds, we witnessed robust growth in both developed and emerging economies. Looking ahead, we believe that this sector will continue to present good opportunities for us as customers in the process automation industry look to push for growth and development. The Southeast Asia region, namely markets such as Singapore, Indonesia, Malaysia, Thailand and Vietnam will continue to grow and present great potential for our industry. For 2012, we will make strategic investments in technology and new products as well as human capital in order to deliver our customers’ needs. We believe that the process automation industry will continue to demand for innovative products, people, and services offered via a global delivery model in order to better manage economic turbulences. In Southeast Asia, our process industry customers have responded extremely well to technologies and solutions that bring operations excellence, overall asset effectiveness, and business efficiency, therefore a higher return on capital employed.

Scott Teerlinck, regional director, Rockwell Automation Asia Clearly, we are watching the global economy very closely. Without question, economic health in Europe and North America will have an impact within Southeast Asia. We have already witnessed varying responses from our customers in the form of changing investment timelines for new plants, production lines, and their purchase of capital machinery. That being said, I believe we must keep the uncertainly in perspective; even if we do see moderation to GDP’s and Industrial Production indices, within Asia those figures are still toward the higher end of the global range. In other words, even if things slow across Southeast Asia, I fully expect we will continue to have many opportunities for growth in the coming quarters. We will very carefully select the areas in which we focus — in other words ‘pick our battles’ — to help ensure our success and achieve our goals in the short term.

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ENQUIRY NO. 366

David Chia, MD, Beckhoff Automation

Feb/Mar 2012 | industrial automation asia  63


features

“With energy typically representing the single largest controllable expense for most businesses, having a comprehensive energy management program in place can generate savings of up to 30 percent.” — Ang Koon San, president, Schneider Electric Singapore and Brunei Ang Koon San, president, Schneider Electric Singapore and Brunei In view of the economic uncertainty predicted to last throughout 2012, one of the largest challenges facing the industrial landscape today and over the coming year would be enhancing or maintaining business performance while improving efficiency and productivity in order to remain competitive. At the same time, businesses have to ensure that production schedules, emissions targets and quality requirements still continue to be met. In the long term, another huge challenge facing our industry would be the energy dilemma. Energy demand is expected to double by 2050, yet the world needs to reduce carbon dioxide emissions by half in order to avoid drastic climate changes by then. Renewable energy sources do contribute to solving the energy dilemma but in themselves are not enough to change the energy mix. As a result, businesses are challenged with getting more out of their energy while cutting down on carbon emissions. As energy demands escalate, one of the most acute pain points is actually the fact that for every three units of energy created at the power plant, only one makes it to the point of use. It follows then, that the best way to improve efficiency, cut costs and reduce energy consumption is to cut down on this energy wastage via implementing holistic energy management solutions. It is a solution that will most likely deliver the best returns for businesses while saving the earth at the same time. A great way for organisations to tackle the economic slowdown is by focusing on improving efficiency and productivity to reduce operational costs. As mentioned above, implementing sound energy management practices will be crucial in attaining these savings. With energy typically representing the single largest controllable expense for most businesses — contributing to about a third of operating costs — having a comprehensive 64  industrial automation asia | Feb/Mar 2012

energy management program in place can generate savings of up to 30 percent. Such savings can help businesses gain a competitive advantage by making their products and solutions more cost-effective and hence attractive in a time of belt-tightening due to economic uncertainty.

Eddie Habibi, founder and CEO, PAS Although the global economic slowdown that has engulfed Europe and America since 2008 began to impact the economies of several Asian countries last year, PAS managed to double its business in this region through organic growth. We anticipate, over the next eighteen months, that slowdowns in China and Southeast Asia will drive down demand for basic consumer goods, which will in turn lead to reduced demand for refining and petrochemical products. As revenues flat-line for manufacturing firms in the region, we expect these companies to cut back their operating expenses and reduce investments in capital projects in order to maintain profitability. The best remedy to sustain a respectable level of profitability during uncertain economic times without impacting safety is to reduce cost through two important measures: (1) improve productivity of personnel, and (2) minimise costly unplanned shutdowns. PAS is uniquely positioned to thrive during times of austerity since our solutions directly improve personnel productivity and plant safety. Our operator-centric PlantState Suite software greatly improves the operator’s situation awareness, enabling the mitigation of abnormal situations before they occur. ENQUIRY NO. 1802


The regional exhibition and conference in Asia for the RFID industry 25 – 27 April 2012, Suntec Singapore Join us to gain industry intelligence, network with over 8,000 decision makers from various industry verticals and form new business relationships.

Event at a glance 8,000 sqm of exhibition space Over 8,000 quality attendees from over 50 countries / regions 60 hours of networking at ‘by invitation’ only events 20 countries to be represented on the exhibition floor 3 Group Pavilions – China, France and Singapore 1 C - level, 2-day RFID conference 1 educational post-conference workshop

Pre-register online before 13 April 2012 for your FREE visit to the exhibition! Scan this QR pattern with the camera on your smartphone to register now! Don’t have a smartphone? You can also register on our website.

Media Partner

@cardsblog Hashtag: #rfidasia Official Blog – The Wall: http://blogs.terrapinn.com/cards/

ENQUIRY NO. 379

Follow

us on

www.rfidworldasia.com.sg


EVENT REVIEW

SCM Logistics World 2011 SCM Logistics World was held from October 18-21, 2011, at Marina Bay Sands, Singapore. Already in its 7th year, the 2011 event had 70 key speakers and more than 500 participants from from across 20 different countries to look into ways to reduce costs, increase customer satisfaction, improve the ROI of supply chain systems, streamline procurement, demonstrate regulator y compliance and risk management capabilities and ultimately contribute towards enhancing a company’s profitability. The theme for the 2011 conference revolved around ‘Agility Through Innovation’. The conference focused on discovering growth and development opportunities beyond 2011 in Asia, understanding the risks and challenges in an emerging market, innovating demand forecasting strategies that work in a dynamic and ever changing environment and cross-learning and benchmarking from the best in the industry. 66  industrial automation asia | Feb/Mar 2012

The programme for the four days of the SCM Logistics World 2011 included: • Next generation supply chain leadership summit. • Chief supply chain cfficers symposium, logistics leaders symposium and CFO & CPO summit. • Four industry focused tracks on high tech, retail & CPG, chemical, oil & gas, automotive and industrial & heavy manufacturing. • Four high strategy forums on technology, sustainability, performance and customer centricity. • Three geography focused tracks on ASEAN, India and North Asia.

• Two targeted post conference workshops. SCM Logistics World 2012 For the 2012 series, to be held from October 18-21, 2012, the event will consist of four conferences, two summits and numerous workshops. The SCM Logistics World, Manufacturing Show Asia, ProcureLog and Translog will collectively bring together over 800 senior leaders from manufacturing companies, logistics providers, software solution providers, ports, terminals, economic development zones, banks, and more. October 18-21, 2011 Marina Bay Sands, Singapore ENQUIRY NO. 1901


spend on checking the potential issues in your production floor with IR Thermography. • Enhance your machineries lifespan through early detection of power anomalies. • Best practice in effective electrical signal capturing and analysis to minimise bad electrical signal that cause expensive production downtime.

Fluke Predictive

Maintenance Seminar

Fluke (Singapore) hosted its Predictive Maintenance Seminar on November 22, 2011, at the Mapletree Business City, attended by approximately 70 of Fluke’s customer base. Businesses today rely so heavily on reliable electrical systems that a failure in an electrical distribution system will result in high costs in ‘lost business’ than the actual cost to replace the failed equipment. Effective predictive maintenance and with good practice on an instrumentation calibration program will help in predicting up-coming issues that results in less equipment needing to be replaced or having unwanted and expensive breakdowns. The company, Fluke, develops test tools that are safe, reliable and convenient for troubleshooting and diagnostics that are critical

for predictive maintenance. In this seminar, the company aimed to share the importance of predictive maintenance for electrical and instrumentation applications. There were two sessions, a morning session on predictive maintenance of electrical applications and an afternoon session on predictive maintenance of instrumentation applications. Outline Of Seminar: Morning Session — Electrical The morning session focused on the electrical aspects of maintenance, and if maintenance has been carried out effectively and safely. Topics Of Morning Session: • Right tools selection to keep technicians safe and efficient. • Shorten 80 percent of your time

Afternoon Session — Instrumentation Thousands of sensors are deployed in process plants. These sensors are commonly connected to smart transmitters which monitor the process conditions to ensure production quality. Calibrating these transmitters will ensure precision signal conversion. Usually, it is more practical to perform calibration at site. In order to perform these calibrations at site, you will need to carry more than one tool and be subject to human errors. In the afternoon instrumentation seminar, instrumentation calibration was discussed and how technicians can carry less tools yet carry out these maintenance tasks effectively. Topics Of Afternoon Session: • Why we need calibration and the effective process tools that enable you to carry less, but perform more maintenance tasks. • Maintenance of Fieldbus Industrial Control Signals to prevent production breakdown. • Leverage on thermography technology to identify potential issues in insulation, pipings, steam traps, and more, in process plants. November 22, 2011 Mapletree Business City Singapore ENQUIRY NO. 1902 Feb/Mar 2012 | industrial automation asia  67


products & Services Adept Technology:

Agilent Technologies:

6-Axis Robot

I/O Connectivity

Adept Technology has introduced the Adept Viper s1700D, a high-performance six-axis robot. The Viper s1700D offers a long reach of 1.7 m and a payload capacity of 20 kg. The robot has been designed for applications that require fast and precise automation, the Viper s1700D robot is ideal for material handling, machine tending, packaging, cutting and assembly. The s1700D robot features Adept ACE software, which deploys the robot through a user-friendly interface. The Ethernet TCP/IP capability allows the robot to be controlled through a PC, PLC, or controller.

From standard GPIB and RS-232 interfaces to PCI/PCIe, USB or LAN interfaces, stay connected to instruments with Agilent’s family of I/O connectivity hardware, which include GPIB boards, USB converters, LAN converters, cables and adapters. Each product comes with industry-standard I/O libraries for users to utilise their existing software programs as well as mix and match test instruments and software from different vendors in a single system.

Enquiry no. 1903

Enquiry no. 1905

Advantech: Wireless

ASI:

Integrated with wireless functionality, power management, and I/O technologies, Advantech’s WSN-4000 series are suitable for data acquisition. Based on the 2.4GHz IEEE 802.15.4 wireless standard, networks can be easily deployed and extended. Low data rates and low-duty cycles make WSN-4000 series possible to act as standalone devices, providing low power consumption and cost-effective remote I/O solutions. The product uses the industrial communication protocol, Modbus RTU. WSN-4000 series products have network coverage of 250m for the gateway and IO node as well as 1,000m for the router.

Automation Systems Interconnect has launched a new line of miniature photoelectric sensors available in diffuse proximity, fixed focus proximity, polarised retroreflex, retroreflex for transparents, and through beam. The S8 Series offers good detection performance, which is the ideal solution for the food and beverage industry, electronic plants, packaging lines, test and assembling machines and automotive. Also available as laser models with coaxial polarised retoreflex and background suppression. A highlight of the laser version is the extremely focused spot below 1 mm and switching frequencies reaching 10 kHz making it amongst the highest on the market.

Router Node

Enquiry no. 1904 68  industrial automation asia | Feb/Mar 2012

Photoelectric Sensor

Enquiry no. 1906


products & Services

Banner:

Beckhoff: Control Panel

Light Curtains

And Panel PC

Banner Engineering has introduced the EZ-SCREEN low-profile safety light curtain with integral muting, a control reliable, Type 4 Category 4 PLe machine safety product. Low-profile safety light curtains are designed for use on smaller production machines, yet are robust enough for large power presses. The rollout of the new integral muting models extends the existing EZ-SCREEN family to provide additional hookup options and functionality. The EZ-SCREEN LPM with integral muting has a sensing range that spans from 100 mm to 7 m (4" to 23'). Seven different, predefined muting configuration options are available, including bypass, mute-dependent override, mute enable, and mute-cycle time extensions for ‘L’ — style cell exit applications making the EZ-SCREEN LPM with integral muting incredibly versatile.

The CP2xxx and CP3xxx Control Panel and Panel PC series announced by Beckhoff Automation are characterised by a modern operating concept with multi-touch display as well as a contemporary, elegant device design. In the execution as built-in or mounting arm devices, the aluminium and stainless steel panels are robust and are designed for use under harsh industrial conditions. Widescreen panels in various sizes and resolutions are available in addition to the classic display sizes in 4:3 format. The new panel generation also offers numerous advantages to single-touch users, such as an optimised price performance ratio with savings of up to 28 percent compared to previous devices.

Enquiry no. 1907

Baumer: Laser Sensor For

Enquiry no. 1909

Belden: Modular Industrial

Demanding Applications

Patch Panel

With three sensors Baumer expands its OADM 13 family of distance measuring laser sensors. So far highly glossy surfaces, such as plastic parts or varnished sheet metal, were a major challenge. Now the sensors can be used for applications with these conditions. They are able to process object reflectivities down to 0.5 percent. The sensors can be used in handling applications during semiconductor production where the fine laser beam is an advantage. In the graphics industry or in metal and sheet metal working the improved measuring accuracy at colour transitions as well as the sensitive receiver provide the basis for more reliable measurements.

Belden has introduced the new MIPP, a termination panel for cables that need to be connected to active equipment such as switches, Industrial Ethernet devices and any other device with an Ethernet link, offering greater system reliability and ease of installation. MIPP provides the ideal connection between Belden cables and Hirschmann switches and is designed to have the same look and feel as the Hirschmann range of products. The modular design and their compact dimensions, up to six individual modules can be combined in any permutation to create a large single patch panel, to which, both fibre and copper cables can be connected at the same time. When required, each module can be easily removed or replaced for system flexibility.

Enquiry no. 1908

Enquiry no. 1910 Feb/Mar 2012 | industrial automation asia  69


products & Services

B&R: Bus Controller

Markes International:

The Powerlink X67 bus controller from B&R comes with IP67 protection and is equipped with 12 digital channels that can be configured as either inputs or outputs, the module can be perfectly adapted to any task. An analogue channel for 0 to 20 mA further extends the range of potential applications for the Powerlink bus controller. The freely configurable input filter provides additional flexibility for project implementation. Furthermore, one input can be used as a counter input for an event counter. All connections are designed for M12 standard plugs. It has a remote backplane allowing expansion to include additional X67 or X20 modules over long distances.

Markes International has announced that it will be launching a new instrument, the CIA Advantage. Designed for the analysis of Volatile Organic Compounds (VOCs) in air and gas that is sampled using canisters, the CIA Advantage allows analytical chemists to analyse a wide range of analyte concentrations without the need for dilution, saving time and meeting an industry need for more flexible solutions. Due to the inbuilt sorbent tube functionality, the instrument has the capacity to analyse an extended range of compounds while improving workflow productivity. CIA Advantage systems are fully compliant with the US Environmental Protection Agency Method TO-15, allowing users to have confidence in results.

Canister Analysis

Enquiry no. 1911

Endress+Hauser: Flowmeters

Enquiry no. 1913

Objet: Multi-Material

3D Printer

The CNGmass Coriolis flowmeter series from Endress+Hauser is approved by NTEP in the US and five other international standards organisations for custody transfer of Compressed Natural Gas (CNG) and for fueling vehicles with CNG. Available in three common sizes from 3/8 to one inch, the CNGmass measures mass flow up to 330 lb/min (150 kg/min) at fluid temperatures up to 257F (125C) degrees and pressures to 5,080 psi (350 bar). The instrument measures direct mass or corrected volume flow with 0.5 percent accuracy to meet custody standards. It also outputs temperature and density. Enquiry no. 1912 70  industrial automation asia | Feb/Mar 2012

Objet has developed the Objet260 Connex, a compact addition to the company’s family of multi-material 3D printers. The printer is based on the company’s inkjet 3D printing technology — the rapid prototyping system that is able to jet two materials at the same time. The technology allows users to select from a range of composite materials when building 3D models, such as the company’s recently released ABS-like material. The system can also print a model replica made of up to 14 individual materials in a single print run. Enquiry no. 1914


Calendar Of Events 2012 FEBRUARY

08 – 11 Enertech World Expo 2012

Bombay Exhibition Centre - NSE Exhibition Complex India Chemtech Foundation Email: conferences@jasubhai.com Web: http://www.chemtech-online.com/ enertech/

09 – 10 Intermodal Asia 2012

Intercontinental Melbourne The Rialto Australia Transport Events Management Email: enquiries@transportevents.com Web: http://www.transportevents.com/

14 – 17 CIAACE 2012

China International Exhibition Centre (CIEC) China Yasn International Exhibition Co., Ltd. Email: info@yasn.com.cn Web: http://www.ciaacexpo.com/

21 – 23 Offshore Asia

Kuala Lumpur Convention Centre Malaysia Pennwell Conference and Exhibitions Email: Headquarters@PennWell.com Web: http://www.offshoreasiaevent.com/

29 – 2 Mar Propak Vietnam 2012

Saigon Exhibiton & Convention Center (SECC) Ho Chi Minh City, Vietnam Bangkok Exhibition Services Ltd Email: exhibit@oesallworld.com Web: http://www.propakvietnam.com/

march 07 – 09 SIAF Guangzhou 2012

China import and export fair complex Email: sps@china.messefrankfurt.com Web: http://www.siaf-china.com/

14 – 16 Asia Pacific Maritime

Marina Bay Sands Email: apm@reedexpo.com.sg Web: http://www.apmaritime.com/

27 – 29 Asia Water 2012

Kuala Lumpur Convention Centre (KLCC) Email: airin@ambexpo.com Web: http://www.asiawater.merebo.com/English/ english.html

28 – 31 Inatronics 2012

JIExpo Kemayoran Email: info@gem-indonesia.net Web: http://www.inatronics-exhibition.net/

april

3 – 6 Automation World 2012

Coex Convention and Exhibition Center, Seoul Korea Coex Email: automationworld@coex.co.kr Web: http://automationworld.co.kr/index. html?TPL=en_main.tpl

23 – 27 Hannover Messe 2012

Deutsche Messe Hannover Germany Deutsche Messe AG Hannover Email: info@messe.de Web: http://www.hannovermesse.de/home

24 - 26 Semicon Singapore 2012

Marina Bay Sand Singapore Email: lchan@semi.org Web: http://www.semiconsingapore.org/

25 – 27 RFID World Asia 2012

Suntec Singapore International Convention and Exhibition Centre Singapore Terrapinn Email: audrey.leong@terrapinn.com Web: www.rfidworldasia.com.sg

Bangkok, Thailand UBM Asia (Thailand) Co Ltd Email: info@cmpthailand.com Web: http://www.renewableenergy-asia.com/

12 – 14 Green Energy Asia 2012

Kuala Lumpur Convention Center (KLCC) AMB Exhibitions Sdn Bhd Email: support@ambexpo.com Web: http://www.biztradeshows.com/trade-events/ green-energy-asia.html

13 – 16 Propak Asia 2012

Bangkok International Trade & Exhibiton Centre Singapore Bangkok, Thailand Bangkok Exhibition Services Ltd Email: info@besmontnet.com Web: http://www.propakasia.com/

July 3 – 6 MTA Vietnam

Saigon Exhibition & Convention Centre Ho Chi Minh City Singapore Exhibiton Services Pte Ltd Email: mta@sesallworld.com Web: http://www.mtavietnam.com/

11 – 13 Indo Renergy 2012

Grand City Convex Surabaya Surabaya, Indonesia PT. Napindo Media Ashatama Email: agung@napindo.com Web: http://www.indorenergy.merebo.com/English/

May 15 - 19 Automex

PutraWorld Trade Centre Kuala Lumpur, Malaysia Email: info@tradelink.com.my Web: www.tradelink.com.my

18 – 20 Propak China 2012

17 – 20 IA Robotics 2012

Bangkok International Trade & Exhibiton Centre Bangkok, Thailand UBM Asia (Thailand) Co Ltd Email: info@cmpthailand.com Web: http://www.intermachshow.com/

22 - 24 Industrial Automation Kuala Lumpur

Kuala Lumpur Convention Center (KLCC) Facon Exhibitions Sdn Bhd Email: sales@faconex.com Web: http://www.tradeshowz.net/trade-eventdetail/industrial-automation-kuala-lumpur.html

June

Shanghai New International Expo Centre Shanghai, China China International Exhibitions Email: vicky@chinaallworld.com Web: http://www.propakchina.com/en/index.asp

August 29 – 1 Sep Taipei International Industrial Automation Exhibition 2012

Taipei World Trade Center Nangang Exhibition Hall Taiwan Chan Chao International CO., LTD. Email: show@chanchao.com.tw Web: http://www.chanchao.com.tw/automation/en/ index.asp

06 – 09 Renewable Energy Thailand 2012

Bangkok International Trade & Exhibiton Centre Singapore To be considered for inclusion in the Calendar of Events, send details of event (name, date, venue, organiser contact) to: The Editor IAA Eastern Trade Media Pte Ltd. 1100 Lower Delta Road, EPL Building, #02-05, Singapore 169206 Tel: (65) 6379 2888 • Fax: (65) 6379 2805 • Email: iaa@epl.com.sg


Advertising Index

64

|

IndustrialAutomationAsia

ADVERTISING I N D E X

ADVERTISER

PAGE NO ENQ NO

ABB Pte Ltd

IFC

138

Advantech Co. Singapore Pte Ltd

41

373

19/53

360/359 377

Agilent Technologies Singapore (Sales) Pte Ltd Apocope Media Consultancy

43

Beckhoff Automation Pte Ltd

IBC

361

Belden Singapore Pte Ltd

49

365

Centre for Continuing Education/Nanyang Technological University

57

357

Faulhaber Singapore Pte Ltd

37

376

Flir Systems Co., Ltd

3

364

Fluke South East Asia Pte Ltd

55

372

Fuji Electric Asia Pacific Pte Ltd

7

264

Hitachi Asia Ltd

61

266

HEAD OFFICE

MEDIA REPRESENTATIVES JAPAN:

IFM Electronics Pte Ltd

33

370

35/47

367/368

61

371

OBC

334

JJ Lapp Cable (S) Pte Ltd National Instruments

5

250

Piab Asia Pte Ltd

63

366

Pt. Gem Indonesia

51

358

Rockwell Automation South East Asia Ltd

1

363

Schneider Electric IT Singapore Pte Ltd

23

362

Semicon Singapore

31

378

Sick Optic Electronic Pte Ltd

21

369

Siemens Pte Ltd

15

374

Terrapinn Pte Ltd

65

379

UBM Asia (Thailand) Co., Ltd

39

375

SINGAPORE Eastern TRADE MEDIA PTE LTD 1100 Lower Delta Road #02-05 EPL Building Singapore 169206 Tel: 65-6379 2888 Fax: 65-6379 2805/6379 2806 SINGAPORE: salesIAA@epl.com.sg

Igus Singapore Pte Ltd Mitsubishi Electric Asia Pte Ltd

ADVERTISING SALES OFFICES

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 FOUR WEEKS before the date of publication. Please contact our nearest advertising office for more details.

This index is provided as an additional service. The publisher does not assume any liability for errors or omissions.

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| EK11-06E |

A complete servo drive can look as compact as this. Directly connect a servomotor and resolver to a 12 mm wide Bus Terminal.

www.beckhoff.com.sg/EL7201 The EL7201 servo terminal for the Beckhoff EtherCAT Terminal system integrates a complete servo drive for motors up to 200 W into a standard terminal housing: Direct connection of servomotor, resolver and holding brake to a 12 mm wide Bus Terminal Considerable reduction in space requirements as well as wiring and commissioning costs Integrated fast control technology designed for highly dynamic positioning tasks The servo terminal supports synchronous motors with a rated current of up to 4 A. The combination of AM3100 servomotor and servo terminal represents an inexpensive servo axis in the base performance range. IPC I/O Motion Automation

ENQUIRY NO. 361

Beckhoff Automation Pte. Ltd. Phone: + 65 6635 5000 info@beckhoff.com.sg Beckhoff Automation Sdn. Bhd. (889044-H). Phone: + 60 (3) 7731 8388 info@beckhoff.com.my


ENQUIRY NO. 334


IAA Feb Mar 2012