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June/July 2013 IndustrialAutomationAsia

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June/July 2013

MICA (P) 010/07/2012 | ISSN 0219/5615 | PPS 1561/06/2013 (022960)

Robotics | Motion Control | Smart Sensing Technology | Water Solutions

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AC DRIVES | SERVO DRIVES | CONTROLLERS | ROBOTS | SYSTEM ENGINEERING

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YASKAWA’s advanced mechatronics equipment and rich expertise in motion technology makes a real contribution to improved speed and precision industry worldwide. Providing solutions to our customer’s machine design needs, YASKAWA Solution Center can understand the concepts of our customers and provide a variety of optimized component product solutions.

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IAA will be releasing an energy guide later this year, giving you exposure to the rising Asian energy sector.

ISSUES & INSIGHTS

22

The Future Of Industrial Robotics

24

Case Study: Zero-Defect Assembly

In the globalised economy, manufacturers are increasingly using automation strategies in their plants to gain a competitive advantage. By Enrico Krog Iversen, Universal Robots

The use of robots sets a benchmark in the manufacture of heavy-duty diesel engines in China. By Laura Schwarzbach, Kuka Roboter

Process CONTROL 22

26

Case Study: A Symbiosis Of Technology And Art

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Case Study: Quality Control With 3D Vision

‘Kinetic Rain’ is a dynamic sculpture located at Terminal One of Changi Airport in Singapore. This artwork’s implementation was aided by the technology of PC-based control. Contributed by David Chia, Beckhoff Automation

In the German beverage industry, crates are checked for missing bottles before leaving the plant. A vision sensor detects small irregularities that would not have been detected with conventional photoelectric sensors. This ensures quality and reliability are maintained. By Andreas Biniasch, ifm electronic

SOFTWARE & NETWORKS

32

Embedded Vision Technology

The incorporation of visual data is taking embedded systems to new levels of performance. By Casey Weltzin, National Instruments

26

INSTRUMENTATION & MEASUREMENT

35

The Future Of Smart ID

38

Smart Sensing: Situational Awareness

42

A Sense Of Things To Come?

IAA spoke with Ram Ramaprasad, director of product management, Card Printing Solutions, and Dickson Chew, director for technical operations (Asia Pacific), Zebra Technologies, on the Smart ID market and the implications of Near Field Communication (NFC) for the industry. By Mark Johnston

Plant safety can be improved by making available important information to the relevant crew members at the right time. Smart sensing in this regard can improve the situational awareness of plant staff and as such improve operational effectiveness and safety. By Jonas Berge, Emerson Process Management

30 2  industrial automation asia | June/July 2013

The technologies packed into a small sensor can result in big performances. By Joson Ng


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Connect with us at

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energy

44

Asian Expansion

IAA spoke with Francis Cheng, GM for Industrial Automation, Mitsubishi Electric Asia, on the market potential in Asia, and the company’s new development centre in India. By Mark Johnston

SECTOR SPOTLIGHT

46

Case Study: Improving Quality Through Automation

Improving water quality, and leak detection while increasing energy savings are some of the outcomes of a Swedish energy company upgrading its control infrastructure. By Lars-Goran Dybeck, Blyerts

46

FEATURES

50

IAA caught up with exhibitors at MTA 2013 to talk about their new products at the show, as well as their plans for the ASEAN region. By Joson Ng

50

54

IAA At MTA 2013

Cover: Kuka Systems Industrial Automation Asia (IAA) is published 8 issues per year by Eastern Trade Media Pte Ltd 1100 Lower Delta Road #02-05 EPL Building Singapore 169206 Tel: (65) 6379 2888 • Fax: (65) 6379 2805 Website: www.iaasiaonline.com Email: iaa@epl.com.sg

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Optimising PLC Network Performance And Management

Three facets of Programmable Logic Controller (PLC) network optimisation will be discussed that can ensure network availability, simplify network monitoring and configuration, and maximise network flexibility. By Gary Chang and Mark Wu, Moxa

EVENTS

58

Hannover Messe 2013

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

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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Industry News

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Products & Services

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Calendar of Events

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EDITOR’s PAGE

Published By:

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

Economics Of Automation

MANAGING DIRECTOR

Kenneth Tan editor

Joson Ng josonng@epl.com.sg

Assistant editor

Mark Johnston markjohnston@epl.com.sg

Editorial Assistant

With Asian economies soaring ahead, automation will play an

Shaik Siti Shairah Bee sitishairah@epl.com.sg

integral part in keeping this pace alive. Improving production processes and collaboration are important elements in successful

Graphic Designer

economies. Energy is another factor worth considering, as

pehloonchin@epl.com.sg

Peh Loon Chin

without enough affordable energy, there is nothing to fuel

Senior Sales Manager

Derick Chia

economic growth.

derickchia@epl.com.sg

Robotics, in particular, have importance in countries where

senior CIRCULATION EXECUTIVE

Brenda Tan

manual labour is abundant, such as China. The implementation of

brenda@epl.com.sg

automated solutions, especially robotics, has increased dramatically in recent years. In 2010, the penetration of robots increased sharply, reaching 52,290 installed units. In 2011, the sales volume of new

Contrtibutors

Enrico Krog Iversen, Laura Schwarzbach, David Chia, Andreas Biniasch, Casey Weltzin, Jonas Berge, Lars-Goran Dybeck, Gary Chang, Mark Wu

industrial robots increased by 51 percent year-on-year to around

Editorial Consultants

22,600 units, which turned out to be the highest growth rate in the

Jim Pinto Industry Analyst

world. By 2014, it is projected that China will need 32,000 units of

Alastair Ross

industrial robots, becoming the world’s largest robotic market.

Director, Codexx Associates Ltd

Increasing concerns surround safety and working conditions, as well an increase in wages appear to be driving this growth. It is

supported by:

apparent that today's economy automation strategies are of vital importance to stay competitive in a globalised age. Not just by employing robotics, but also intelligent technologies at large, be they smart sensors, intelligent software, or adaptive processes. The future of automated processes looks bright, especially in

EASTERN HOLDINGS LTD executive Board

more labour intensive markets, such as China. Whether this be

Chairman

Stephen Tay

robotics, or simpler elements, including smart sensors that send their signals back to control motion or register a fault and/or set off an alarm. Such technology also include embedded systems capable of processing complex data. Also, in Asia, energy efficiency has become a hot topic. These topics, and more, can be found in this issue of IAA.

GROUP EXECUTIVE DIRECTOR

Kenneth Tan

etm

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Trade Media Pte Ltd an Eastern Holdings Ltd company

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Industry News

IAA will be releasing an energy guide later this year, giving you exposure to the rising Asian energy sector.

Eastman Set For Sustainable Growth In Asia Pacific Singapore: Eastman Chemical Company has completed its Asia Pacific Technical Centre in Alexandra Technopark, Singapore. The technology centre comprises of added technological capabilities in chemicals research and development, and a 24/7 laboratory facility redesign aimed at energy savings of up to 50 percent. The centre, which first opened in 1997, plays a strategic role in the positioning of both the company and Singapore as a benchmark centre for chemicals and materials research in the region, and further reflects the company’s vision for connecting science with sustainability. The centre also absorbs the Solutia Technical Services Team following the completion of the US$4.8 billion acquisition of Solutia in mid-2012, the largest acquisition in the company’s history. It plans to further strengthen local headcount in the next few years to grow the performance films and Interlayers businesses in Asia Pacific as

The technology centre comprises added technological capabilities in chemicals research and development, and a 24/7 laboratory facility redesign aimed at energy savings of up to 50 percent.

part of a diversified portfolio strategy for sustainable growth. Furthermore, with the philosophy of ‘all in for safety’, the company is aiming to achieve a goal of zero-injuries. The

1,128 sq m technical centre is compliant with local regulations with increased petroleum and flammable storage capacity to address hazard issues.

ThyssenKrupp Doubles Its Vodafone Contract Volume Singapore: Vodafone has been selected by ThyssenKrupp to provide mobile communications services in 30 countries across Asia-Pacific, Europe and Latin America. The 13 countries across Asia-Pacific that will be covered under this 42-month contract include Hong Kong, Indonesia, South Korea, Malaysia, Philippines, Singapore, Taiwan, Thailand, Vietnam, Australia, India, Japan and China. As a global mobile services provider, Vodafone will provide the industrial corporation with 60,000 mobile voice and data connections and services including mobile device management. The company will also provide ThyssenKrupp with 50,000 Machine-to-Machine (M2M)

8  industrial automation asia | June/July 2013

cards which will aid the remote control and maintenance of industrial products including tens of thousands of this company's elevators and their emergency intercom systems. The contract represents a doubling in volume of Vodafone's previous contract with ThyssenKrupp. Apart from managed mobility, the company will be serving 16,000 new mobility connections in AsiaPacific. At least 40,000 M2M cards will also be installed in elevators making use of the company’s global data service platform, which will allow ThyssenKrupp to increase their speed of implementation and reduce the cost, complexity and risk traditionally associated with deploying such M2M projects.


ENQUIRY NO. 585


Industry News

Siemens And Diamond Energy To Pilot Demand Response In The Commercial Building Sector In Singapore Singapore: Siemens and Diamond Energy have signed a memorandum of understanding, to collaborate on a multi-phased Demand Response services implementation. The collaboration will commence with a pilot project that aims to demonstrate the feasibility of implementing customised technology and solutions to deploy Interruptible Load (IL) operations, and to explore demand response in The Siemens Centre in Singapore. The existing IL scheme in the National Electricity Market of Singapore enables consumers to be paid in return for having a portion of their electricity supply on standby for temporary interruption. Demand Response is a further enhancement to the electricity market which allows consumers to reduce or shift their power usage during peak demand periods in exchange for payments. In this way consumers are rewarded for being flexible in their electricity consumption and are able to benefit from having lower electricity purchase costs. Under a multi-year partnership, a pilot programme will be implemented by the two companies in a first of its kind pilot project at The Siemens Centre in Singapore. Siemens will supply components such as smart meters and other communication equipment. It will also conduct site surveys for equipment installation, and supervise installations

(L-R) Peter Halliday, head of building technologies, Siemens ASEAN; Anand Menon, CTO, smart grid, Siemens ASEAN; Rageni Chandralela, head of smart grid, Siemens; Lothar Herrmann, CEO, ASEANPacific, Siemens; Chee Hong Tat, CE, EMA; Zainul Abidin Rasheed, chairman, Diamond Energy Group; Dallon Kay, president & CEO, Diamond Energy; Steffen Ender, city account manager, Siemens

with engineering services provided by Diamond Energy. Diamond Energy, one of the largest Interruptible Load Aggregators in the National Electricity Market of Singapore, will manage the IL operations and the pilot demand response program using its proprietary platform. It has been working with the industrial and manufacturing sectors to participate in the IL scheme since 2006. Following the completion of the pilot project, both companies intend to showcase and present the technology and solutions under the pilot project to suitable potential customers in Singapore, to promote further implementations. This pilot project is timely, as the Energy Market Authority (EMA) is reviewing the implementation of a

Demand Response programme in the National Electricity Market of Singapore. Both companies believe that this project will provide a case study on the feasibility of demand side management operations, which can be implemented in commercial buildings. As such, how the overall efficiency of the energy market in Singapore can be improved as a result. The pilot project, when completed, is expected to provide reductions to the energy usage of The Siemens Centre when called upon. Under the IL scheme, Diamond Energy will make payments to the participating contestable consumers based on their availability to reduce their electricity demand by pre-determined quantities when asked to do so.

Kuka Systems Acquires Plant Engineering Business Sterling Heights, US and Augsburg, Germany: Kuka Systems Group has acquired the plant engineering business of privately owned Utica Companies of Shelby Township, MI, a welding equipment specialist and supplier to the automobile industry. With this transaction, the company becomes the number one manufacturing systems supplier to the North American automotive sector. Both companies' core market is automotive assembly although Kuka Systems has diversified successfully into building production lines and platforms for aerospace,

10  industrial automation asia | June/July 2013

energy and other industries. The Utica acquisition primarily covers automobile assembly-related assets in southeastern Michigan. The company will absorb Utica's body structure business that builds car body assembly lines and subsystems. Also being acquired will be products like laser welding heads, net form and pierce systems for high accuracy in joining body sections, standard press room automation for metal stamping and hang-on technologies for installing doors, hoods and other parts on assembly lines.


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Industry News

NXP Security Technology At The Core Of eID Programs Singapore: In the 2013 edition of Cards & Payments Asia, held at Marina Bay Sands, Singapore between April 24 to 25, 2013, NXP Semiconductors shared that it was near completion of its part in the 172 million pieces supplied into the eKTP project. Launched in 2011, the project is said to be one of the largest national eID deployments across the globe. The cards for citizens are part of a nationwide, multi-application, complete eID-system that comprises data capturing solutions, servers, data storage, biometric matching and smart cards, plus various infrastructure and networking solutions. Combining the strong drive of the local companies with the technical expertise of principal suppliers, the local production companies in the

state printing company consortium were able to ramp-up the smart card production and personalisation of the cards and achieve near completion within 18 months. In addition, the technology efforts brought into the project have resulted in growth within the local Indonesian smart card and biometrics industry. As such, the project has also proven to be a valuable investment of governmental funds into the local economy. The project will enable the Indonesian political system to strengthen democracy across the country by de-duplicating the various existing population databases, resulting in a more thorough census and identification of all Indonesian citizens. Once complete, the system can be the basis for many citizen-government

services, proving a citizen’s identity 'beyond any doubt'. It can then be used to open bank accounts, obtain governmental documents such as birth certificates, register ownership of vehicles or property and many similar transactions. In addition, the multi-application capability of the chip technology enables the smart cards to support a large number of voting applications, which reduce the possibility of fraud during elections. This will assist in the government’s aim of building citizen trust in the country’s democracy. Fully compliant with the structure of ICAO LDS-9303, the smart card can also be used as an international travel document, should Indonesia reach agreements on this with neighbouring countries.

ABB Named ‘2013 Company Of The Year’ Singapore: ABB has received the Frost & Sullivan’s ‘2013 Company of the Year’ award in the automation and control market for emerging sectors. The firm selected the company for its focus on emerging end-user sectors such as alternative US energy sources, pharmaceuticals, data centres and smart grids. Automation and control is a mature industry and constantly seeks growth from new and emerging end user sectors. “ABB has demonstrated a successful and focused growth strategy for these emerging industries by understanding customer needs and providing a wide range of product and technology solutions,” said Frost & Sullivan’s Vandhana Venkatesan, senior research analyst for Asia Pacific Industrial Automation and Process Control Practice. “We are honoured by the recognition Frost & Sullivan has given ABB,” said Paul Dennis, group VP, Control Technologies, ABB. Adding: “This distinction spurs us to push beyond the boundaries of traditional automation. With data centres consuming as much energy as some process and manufacturing industries, the market stands to reduce energy consumption through the use of ABB’s automation and control solutions.”

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Paul Dennis, Control Technologies group VP, ABB, receiving the award from Cindy Gan, director, Frost & Sullivan.


Industry News

2013 Vision Developers' Forum Singapore: As part of its launch for the USB3 Vision Standard, Basler has organised a seminar in Singapore and Malaysia as a platform to provide a better understanding of the standard. The seminar in Singapore will take place on July 4 at NTU@one-north (Buona Vista), while the Malaysian installation will be on July 5 at Hotel Equatorial Penang. Conducted by René von Fintel, senior product manager, participants will get a chance to learn more about USB 3.0 technology, the USB3 Vision standard and their benefits.

The standard was officially ratified in January 2013. It is hosted by the AIA (Automated Imaging Association) and represents the standard for the USB 3.0 interface in the machine vision industry. Basler was a founding member and contributed to the development of this standard. USB 3.0 is an interface technology for applications in the areas of industry and medicine, as well as for the mass market. It has transmission bandwidths of up to 350 MB/s, and is also completely ‘plug & play’ ready. Please refer to our calendar of events on page 71 for further details and registration.

Emerson Opens First Flow Calibration And Service Centre For Southeast Asia Singapore: Emerson Process Management announced the opening of its Southeast Asia Flow Calibration and Service Centre in Singapore. Representing an investment of over US$1 million, this ISO17025compliant centre serves customers throughout Southeast Asia with the first in-region internationally-traceable calibration facility. This facility is situated within the company’s existing Southeast Asia Service Centre in Singapore which opened in 2008. Service engineers operating out of the facility will provide calibration, repair and analysis services for the organisation’s Micro Motion and Rosemount flowmeters. This expands the centre’s capability that already includes valve and instrument repair, and service teams that provide onsite support and training. “The opening of Emerson’s Southeast Asia Flow Calibration and Service Centre further complements the company’s flow service footprint in Asia, which also includes service centres in Nanjing and Pudong, China,” commented Scott Anderson, Emerson’s president of Flow Lifecycle Care business at the opening in Singapore. Previously, Southeast Asian customers faced limited options and high operational hurdles to validate flow device calibrations or provide required

The SEA Flow Calibration & Service Centre in Singapore. Local service means minimal process downtime and reduced costs coupled with the quality assurance that calibrations are done with an internationally-certified standard.

third party documentation associated with ISO9000 quality or regulatory requirements. Flow meters often had to be physically removed from operation and shipped overseas for calibration, service or performance diagnostics, resulting in process shutdowns and delays. Local service means minimal process downtime and reduced costs coupled with the quality assurance that calibrations are done with an internationally-certified standard. The service centre operates using an ISO17025 compliant quality management system and is committed to ongoing process improvements to ensure superior measurement quality. Metrological traceability and certification processes ensure reliable measurements in laboratories and

facilities around the world. Micro Motion has certified the calibration equipments C a l i b r a t i o n a n d M e a s u re m e n t Capability (CMC) with an uncertainty of 0.03 percent. This CMC reflects the traceability, technical competence and capability of the calibration equipment available at the facility. In addition to the company’s flowmeter calibration, the centre offers a range of services including flowmeter diagnostics and evaluations, witness inspection services and documentation to establish the quality of calibration, testing and meter repair. Future plans for the service centre include obtaining ISO17025 accreditation and expanding calibration and service capabilities for vortex and magnetic flowmeters. June/July 2013 | industrial automation asia  13


Industry News

Electrical Vehicle Charging Infrastructure Poised For Rapid Expansion In Asia-Pacific Kuala Lumpur, Malaysia: The increasing emphasis on reducing carbon dioxide emissions and ensuring that Electric Vehicles (EVs) constitute 20 percent of the total vehicles on the road by 2030 in several Asia-Pacific countries will lead to the expansion of the EV charging infrastructure market in the region. Tax exemptions and government incentives on EVs and EV charging stations will further encourage the market’s rapid growth. Based on an analysis by Frost & Sullivan, 'Asia-Pacific Electrical Vehicle Charging Infrastructure Market', it has been found that the market’s installation base touched 45,486 units in 2012 and estimates this to reach 1,382,494 units by 2020. The research covers level 1, level 2, Direct Current (DC), and induction chargers. “Subsidies, free parking facilities, and access to special lanes promote the sale of EVs, thereby requiring investments in enhancing EV charging infrastructure,” said Avanthika Satheesh, energy and environmental research analyst, Frost & Sullivan. Adding: “The testing of EV chargers in smart grid pilot projects by Japan, South Korea and Singapore to allow off-peak, vehicle-to-home, and vehicle-to-grid charging will further boost market development.” While the availability of devices with different charging

times offers end users flexibility, the long charging periods of level 1 and level 2 chargers dissuade potential customers. The rapid DC charger takes the least time, but its hardware and installation costs are high. The distance between charging stations, especially in large countries like Australia, also pose a challenge for customers trying to locate a station before their vehicles run out of power. To counter these concerns, governments have invested in EV test-bed programs and battery swapping stations in Asia-Pacific. These stations are designed to replace a car’s battery with a fully charged one within the same time usually spent at a gas station. Australia has initiated level 2 and DC charging trial test beds to analyse the impact of different chargers on the power grid. “Japan, South Korea and Taiwan are conducting research on faster charging systems at lower costs, and will commercialise the resultant products after 2015,” noted Ms Satheesh. “Induction-based wireless chargers are also under testing, and wind energy-powered chargers will gain acceptance in Australia by 2020.” Subscriptionbased services, which increase customer retention, cost recovery, and brand value, are also likely to become popular in the region.

National Instruments Sets Up First Machine Condition Monitoring Lab In Southeast Asia Bangkok, Thailand: National Instruments is setting up a Machine Condition Monitoring (MCM) laboratory in Bangkok, Thailand. The project will be in partnership with King Mongkut’s University of Technology North Bangkok (KMUTNB), Kaowna Electric & Business (KEB), and Mataneepan. The lab at KMUTNB will be a full-fledged training centre with a full spectrum of MCM workshops and professional services that includes motor fault analysis, motor repair and inspection. The lab will cater to companies engaged in large scale manufacturing and other industry and academic stakeholders that are interested in how MCM technologies can help drive operational 14  industrial automation asia | June/July 2013

efficiency, reduce costs, and increase workplace safety. Thailand represents a fast growing market for the company. For more than a decade, the company has been expanding its business in Thailand through strategic partnerships with the academia and industry players in the electronics, manufacturing, automotive, and energy sectors. The ability to monitor remotely is enabled by vibration-based MCM technologies. Mataneepan, AB instrument trading company and a strategic partner in the joint venture, are providing the sensors for the motor fault experiments and simulations at the MCM lab. The MCM lab at KMUTNB is

From left: Chandran Nair, MD, National Instruments (SEA) with assistant professor Panarit Sethakul, dean of the Faculty of Technical Education at King Mongkut’s University of Technology North Bangkok, Thailand.

expected to be fully equipped and ready for customer and academic workshops by the third quarter of 2013.


Industry News

Adlink Technology Hires Former Kontron CTO

Moxa Releases AMI Application Guide Taipei, Taiwan: Moxa has released an Advanced Metering Infrastructure (AMI) Application Guide to outline AMI solutions for smart grids. AMI is an electrical architecture that provides electrical grids with two-way communications for measurement, analysis, and optimisation of energy usage, right down to the level of individual consumer devices. It is a

critical part of the developing smart grid network. AMI systems come in many forms, to meet the wide variety of technological challenges presented by deployments in the field. In this application guide, the full line of the company’s devices are on display, showing how AMI solutions can meet any situational need.

Advantech SRP Business Model Creates New Value In Intelligent Services

Dirk Finstel

Ta i p e i , Ta i w a n : A d l i n k Technology welcomes Dirk Finstel as executive VP of MCPS and CEO of the company's E u ro p e a n h e a d q u a r t e r s . He brings over 22 years of experience in embedded computing, with a background i n c o m p u t e r- o n - m o d u l e technologies and applicationready platforms. Mr Finstel will manage and supervise the operations of Lippert Adlink Technology and the global module computing product segment. He has been a driving force creating industry standards including COM Express and Smart Mobility ARChitecture (SMARC). Before joining the company, he served as the CTO of Kontron, and previously held a variety of executive level positions within the company, including: CEO Sales & Marketing, CEO and VP of Global Research & Engineering. Mr Finstel has over 20 years of experience in the embedded computer technology field.

Taiwan: Advantech announced its 2012 consolidated financial report at the company’s investor conference. Consolidated revenue was reported at approximately NT$27.55 billion (US$920 million), an increase of 4.2 percent compared with 2011; operating margin was NT$10.93 billion (39.7 percent gross margin); and net profit after tax was NT$3.49 billion, which represents about NT$6.22 per share after-tax earnings for the year. The company’s president Chaney Ho said that after two years of transition, the world is entering an intelligent era in technology. This year, keeping this theme in mind, the company will provide services to meet the needs of various industries including providing cloud infrastructure, cloud intelligence services as well as services related to smart cities and the internet of things. The organisation will also develop strategies to augment global distribution and to assist business organisations in taking advantage of the new services. Mr Ho also announced a change to the organisation. In the past, the organisation was structured along geographic or product boundaries. Now, the organisation will be based on vertical sectors and applications. As a result, it has been realigned into three Master Business Groups (MBG): Advantech Automation Sales Eco-Partners

(AASECO) which serves automation system integrators; the Embedded Design-in Group to service equipment manufacturers; and the iServices Group to serve solutions providers in the creation of intelligent services. The organisational changes, chosen to drive business forward, are based on two major criteria: vertical sectors and applications. In the area of global deployment, in addition to continued steady expansion of high-end markets in Europe and North America, research coming from the newly developed collaboration think-tank, the Advantech + Technology Campus (A + TC), has identified more business opportunities in the emerging markets of Russia, India, Israel, the Arab states that make up the Gulf Cooperation Council (GCC) countries, and the Latin American market. Advantech Intelligent Services (AiS) will also provide a Solution Ready Package (SRP) business model to the market. the AiS VP Ken Yu said that as the paradigm in technology continues to shift over the next decade to create the intelligent era, ‘services’ will replace ‘products’ in mainstream market demand. Additionally, following global trends in urbanisation, intelligent cities will flourish, with innovative services, interconnected and integrated devices marking a change in the mode of operation in the industry. June/July 2013 | industrial automation asia  15


Industry News

Mitsubishi Electric To Enhance Global Smart Meter Business To k y o , J a p a n : M i t s u b i s h i Electric Corporation will globally enhance its business relating to smart meters, which are advanced electricity meters with communication functions, in collaboration with its partner Echelon Corporation. The company will integrate Echelon's Open Smart Grid Protocol (OSGP) into its lineup of smart meter products, which are designed for international markets. The organisation’s smart meters will incorporate gridsensing and communication technologies based on Echelon's OGSP and its Networked Energy Services (NES) software as well as the company’s proprietary sensing and metering technologies. The products will be manufactured at Mitsubishi Electric Automation (Thailand) in Bangkok, Thailand and PT Melcoinda in Bogor, Indonesia, both international subsidiaries of Mitsubishi Electric.

Investment Agreement Between Continental And Schaeffler Ends In May 2014 Herzogenaurach, Germany: The Schaeffler Group has given notice of their intention to terminate the investment agreement with Continental in place since 2008. The agreement will be terminated effective May 2014. Continental and the Schaeffler Group together with its shareholders entered into the investment agreement on August 20, 2008 with the involvement of former German Chancellor Dr Gerhard Schroeder. It governs their cooperation

with respect to the company’s position as the largest single shareholder of Continental. Schaeffler currently holds 49.9 percent of the Continental shares. The investment agreement no longer has any practical relevance for either company since key provisions of the agreement expired in August 2012. Schaeffler and Continental have benefitted from their cooperation for years and will continue this cooperation in the future.

Honeywell Selected For Water Distribution Project In Kuwait Kuwait: Honeywell has been selected by Kuwait’s Ministry of Electricity and Water to modernise the water distribution network that supplies more than 280 million imperial gallons of fresh water daily to Kuwait’s growing population. The company’s Experion Process Knowledge System (PKS) will be deployed throughout the Azzour Water Distribution Scheme so that operators at a central location can control a network of six different treatment plants located in Ardiya, Hawally, Salmiya, Failaka Island, Adailiya and the water towers of Kuwait.

The water towers of Kuwait.

At the heart of this control system is the Distributed Server Architecture (DSA), which integrates and manages multiple control systems and control rooms located throughout the water system, simplifying operations, reducing engineering costs and improving system integrity.

Yokogawa Announces ‘Wireless Anywhere’ Concept Amersfoort, The Netherlands: Yokogawa Electric Corporation has introduced its ‘Wireless Anywhere’ business concept on the plant-wide use of ISA100.11a compliant wireless communication technologies for both monitoring and control applications. The company plans to promote this concept to widen the use of ISA100.11acompliant products and related services. This augments the existing ‘Grow’ concept, which encourages the introduction of wireless communication technologies by making a case for their inherent reliability, flexibility, and openness. The ISA100.11a standard ensures high reliability, application flexibility, network expandability, and compatibility with a variety of wired communication

16  industrial automation asia | June/July 2013

standards. ‘ISA100.11a full functional’ field wireless network systems and devices make use of dual redundant technologies that enable a much higher level of reliability, and allow scalability and long-range communications. By following up on the ‘Grow’ concept with this announcement of the ‘Wireless Anywhere’ concept, the company is advocating the use of ‘ISA100.11a full functional’ field wireless systems throughout plants. To this end, it will pursue the following three initiatives: modularising wireless components to accelerate product development, promoting adoption of the ISA100.11a standard, and facilitating host connectivity for both wired and wireless field networks.


Newsdesk

Europe Holds CAN FD Tech Day CAN in Automation (CiA) organised the CAN FD Tech Day Europe in Frankfurt, Germany. More than 80 attendees listened to 10 speakers introducing the CAN FD protocol and discussing requirements. Application cases in automotive as well as industrial control systems were also discussed. Friedhelm Pickard, president of Etas, gave in his keynote speech a historical review of the CAN technology and introduced the requirements for higher speed and larger payload. In more detail, Harald Eisele, chassis system electronics controls integration engineer, from Opel and Dr Marc Schreiner, from Daimler’s research and development division, discussed the requirements of the automotive industry. Dr Tobias Lorenz, open source expert, Etas and Alexander Philipp, software engineer, Port also presented use cases for nonautomotive applications of the CAN FD protocol. Same Chip Coexistence There was some discussion about the coexistence of classic CAN controllers and CAN FD chips in the same network. One of the options is the use of selective wake-up transceivers, which is the direction Opel has decided to adopt. This means all engine control units will be equipped with an ISO 11898-6 compliant transceiver.

Florian Hartwich from Bosch introduced the CAN FD protocol and its functionality. In a separate room Bosch, Etas, Kvaser, Peak, and Vector demonstrated the first CAN FD implementations. In the evening before the event, the companies linked their compatible products to one network. This was so-to-say the first informal CAN FD plug-fest. Conference Announcements In the one-day conference, Francesco Sindaco, director of marketing CAN/LIN, NXP announced a family of CAN transceiver chips qualified for transmission rates up to 2 Mbit/s. In addition, the company will provide CAN transceivers with selective wake-up functionality (ISO 11898- compliant), which are CAN FD tolerant. They can be used for nodes supporting just the classic CAN protocol, so that they do not disturb the CAN FD communication. Radoslaw Watroba, applications engineer, from STMicroelectronics launched CAN FD support for its 32-bit microcontrollers, which will be available in Autumn 2013. There will be versions providing three M-CAN on-chip modules supporting the CAN FD protocol as well as one additional timetriggered CAN on-chip module (ISO 11898-4). Davide Santo from Freescale promised that the US chipmaker will also support the

CAN FD demo by Bosch with 12 nodes running at 10 Mbit/s at a 70 m bus topology.

CAN FD protocol, but this was not an official product release. The company is also developing CAN transceiver chips qualified for higher bitrates than 1 Mbit/s. Etas and Vector announced CAN FD support for their CAN tools. Etas’ Inca software products, tools for calibration, diagnostics, and validation of automotive electronic systems, will support the improved CAN protocol by the middle of 2014. Peter Decker, product manager, Vector stressed that the CANdb format is already prepared for payloads up to 64 bytes. The company uses in its CAN FD interface products its own bus controller implemented in a field programmable gate array. ENQUIRY NO. 4101 June/July 2013 | industrial automation asia  17


Industry Updates

Building On Past Success As in previous years, Profibus & Profinet International (PI) started a notarial record of the devices brought to the market. The forecast, based on a snapshot of the notarial record, shows that 2012 was a good year for Profibus, Profinet and Profisafe. Profinet set a record again in 2012 with 1.5 million new devices brought to the market over the year and expanded the installed base to 5.8 million devices. The number of installed Profibus devices increased in 2012 to over 43.8 million. Of these, 7.5 million can be found in process automation plants. The development of Profisafe continues to be particularly encouraging. With 600,000 Profisafe nodes brought to the market in 2012, the previous year’s figure was exceeded by 50 percent. This increased the total number of Profisafe nodes to 2.15 million.

In 2012, Profinet expanded the installed base to 5.8 million.

Foundation For Success An important foundation for this success is the decision made some years ago by the members of PI to tailor their technologies to cover the range of industrial automation — from factory and process automation to efficient motion control applications including functional safety. Profinet and Profisafe are established in several fields ranging from factory automation and drive applications to motion control. In process automation, Profinet is already used as the backbone, with Profinet and Profisafe used as the inbound/outbound processors in a great many applications. Users 18  industrial automation asia | June/July 2013

Strong interest in Profisafe, which is reflected in the 2.15 million Profisafe nodes.

from the process automation sector are showing interest in using Profinet and Profisafe in the field of continuous processes.

Building Trust PI’s close cooperation with endusers and their organisations,

at the requirements level, which has taken place continuously for years, builds the users’ trust in the technology and in the performance and continuity of the organisation behind it. ENQUIRY NO. 4102


Fieldbus Foundation Co-Sponsors Lounge At Hannover Messe 2013 The Fieldbus Foundation joined the FDT Group, HART Communication Foundation, PI (Profibus & Profinet International) and the OPC Foundation, to host the co-sponsored Field Communication Lounge at the 2013 edition of Hannover Messe, held in Hannover, Germany, from April 8 to 12, 2013. Combined Exhibit With its theme, ‘See, Learn, Compare, Implement’, the aim of the Field Communication Lounge was to create a single area for visitors to see and experience the latest in field communication technologies. Another objective was to discuss how these technologies work together to deliver results to improve plant operations, performance and a company’s profitability. The Lounge’s combined exhibit concept better aligns with the way in which users often integrate field communication technologies at their own facilities. Visitors to the fair had a central location to discuss and compare automation communication protocols — their advantages, their applications, their integration, and how they can work together. Key Features One key feature of the 570 sq m Field Communication Lounge was a common display area in which the organisations exhibited their individual process and factory

The combined exhibit where participating Fieldbus Foundation members demonstrated their interoperable products.

automation communication technologies in dedicated technology kiosks. The lounge also featured a common presentation forum. Exper ts from the five host organisations presented the latest field device communication technology solutions during a series of technical and educational presentations held throughout each day. Fatih Denizer, chairman, Fieldbus Foundation German Marketing Committee, welcomed visitors to the lounge, commenting: “This collaborative concept by leading technology organisations was first introduced at the 2011 Hannover Fair. We received so much positive feedback from show visitors that it was clear that we would adopt the Field Communication Lounge concept again for the major shows in Germany.”

Participating Members “At the Field Communication Lounge, so many well known suppliers of advanced plant communications technology are just a few steps apart so that with just a short stand-tour, visitors can gain a comprehensive overview of the latest developments, make comparisons and discuss integrated solutions with the experts on hand,” concluded Mr Denizer. Several of the Fieldbus Foundation members that participated in the Field Communication Lounge 2013 included: ABB, Beamex, Bürkert, Emerson Process Management, E n d r e s s + H a u s e r, F i e l d b u s International, Fluke, Heinrichs Messtechnik, Honeywell, Invensys, Mesco, Pepperl+Fuchs, Phoenix Contact, R Stahl, Samson, Siemens, and Yokogawa. ENQUIRY NO. 4103 June/July 2013 | industrial automation asia  19


ETG Enjoys A Successful Hannover Fair 2013 This 2013 edition of the Hannover Fair was a success for all participants involved. Compared to the previous year, over 20 percent more visitors came to the exhibition grounds in Hannover from April 8 to 12, 2013, to learn about the latest trends and developments for industrial technologies. At the EtherCAT Technology Group (ETG) member booth the organisation showed over 360 products in the categories of master systems, development products, I/O and gateways, drive technology and safety products. Compared to 2012, the ETG featured 100 more EtherCAT products, an increase of about 30 percent. The products on display were contributed by a total of 63 co-exhibiting member companies which were represented at the organisation’s booth. The devices on display at this year’s show was a small sample of the total available EtherCAT devices worldwide.

Currently, there are more than 2,300 ETG members from 56 countries that produce EtherCAT devices, implement the technology or take advantage of the benefits of EtherCAT — and the trend continues to rise. To date, there are 150 different manufacturers offering EtherCATbased control systems. In addition, the EtherCAT Technology Group showed its 12.5µs cycle time demo as well as its multi axis presenter. To support the ETG at the tradeshow, some of the member companies sent their EtherCAT experts who actively helped demonstrate the power of the technology to visitors from over 30 countries at the fair. In its review of the event, the ETG was again satisfied with its participation at this year’s show in Hannover. To date, the organisation plans to be part of a total of 15 tradeshows around the world in 2013.

Martin Rostan, executive director, EtherCAT Technology Group

At the 2013 edition of the Hannover Fair, the EtherCAT Technology Group welcomed guests from over 30 countries at its booth.

20  industrial automation asia | June/July 2013

ENQUIRY NO. 4104


A Look Back At 10 Years Of EtherCAT

EtherCAT was presented for the first time at Hannover Fair 2003 and has since become an established standard in numerous industries worldwide. Meanwhile, the international user and manufacturer association for EtherCAT, the EtherCAT Technology Group (ETG) has over 2,300 members that support and disseminate EtherCAT technology and drive future developments. This year the ETG marks 10 years of EtherCAT and looks back to reflect on the early days of the technology. EtherCAT is basically the functional principle of the fibre optic-based network, Lightbus adapted to Ethernet. Lightbus, the first fieldbus from Beckhoff Automation, was launched in 1989 and already derived its then performance from the ‘processing on the fly’ concept that EtherCAT also utilises. Accordingly, the working title of the project, from which EtherCAT later emerged, was ‘Fast Lightbus’. Michael Jost, EtherCAT product m a n a g e r a t B e c k h o ff A u t o m a t i o n commented: “It is the unique operating principle that makes EtherCAT so special: fast, flexible, easy to use, cost-effective and therefore successful for 10 years now.” That first presentation of EtherCAT at Hannover Fair 2003 was a highlight in the history of Beckhoff Automation; representatives from every corner of industry visited the booth to have a look at the communication technology. One compelling point was the announcement to develop the technology into an open standard right from the outset. The foundation of the ETG and the publication of the specification as a global IEC standard were other important milestones for the future development

Philipp Rösler, Germany’s federal minister of Economics and Technology and vice chancellor (left), visited the Beckhoff booth at Hannover Fair 2013. Here, Hans Beckhoff, MD, Beckhoff Automation (right) explains the importance of EtherCAT for business development.

of EtherCAT. Meanwhile, most major players in the automation market have now implemented EtherCAT. EtherCAT slave interfaces are today available on standard microprocessors and any Ethernet port can be used for the master. The diversity of EtherCAT applications is compelling: examples include ultra-fast packaging machines, whole steel plants, robots, snow-making equipment, wind tunnels and wind energy systems. Martin Rostan, executive director of the

ETG, looks positively into the future: “Even after 10 years, EtherCAT is still faster than the fastest available CPUs. This is with one version of EtherCAT, namely the first one. Everything that has been added to the technology since are extensions, not modifications: EtherCAT devices from 2003 and 2013 are therefore still compatible. All of these facts are excellent prerequisites for approaching the next 10 years of EtherCAT with strength and confidence.” ENQUIRY NO. 4105

DecJune/July 2012/Jan 2013 | industrial automation asia  21


issues & insights

In the globalised economy, manufacturers are increasingly using automation strategies in their plants to gain a competitive advantage. By Enrico Krog Iversen, CEO, Universal Robots

The Future Of

Industrial Robotics H

ow to stay ahead and compete with manufacturers from lower cost economies? That is the conundrum facing manufacturers in more mature and established Asian economies in Southeast Asia. This is exacerbated by the need to maintain high standards, zero-defects and managing rising manpower costs. This is where automation steps in. Not only can robots break the monotony of a process line and minimise workmanship errors, employees can also be reassigned to other functions where their 22  industrial automation asia | June/July 2013

expertise can be better utilised. Many studies have conclusively found that when deployed in a production process, robots improve efficiency, maximise productivity and contribute to a safer working environment.

Control Quality Robots with low error margins ensure improved quality control and give manufacturers the confidence needed to focus on innovation and improving competitiveness. A robot that operates within an error margin of plus-minus 0.1mm significantly reduces the

time employees spend on quality checks. It also prevents the wastage of resources in rectifying discrepancies, for example. Similarly, the consistent precision that robots deliver, eradicates lapses in employee concentration and crucially, workplace accidents. As such, robots handling riskier or highlyprecise tasks reduce errors; eliminate workplace accidents and increase consistency of quality. It is imperative that e m p l o y e e s a p p re c i a t e a n d embrace technology to fully realise the benefits.


Operational Efficiency And Gains Easily-programmable and deployable robots are a competitive advantage in today’s fast-paced environment where products must be delivered cost-efficiently. By not having a technology expert to setup and install the manufacturing robot means the company reduces deployment time, increases the speed to productivity and maximises on investment. Furthermore, manufacturers save on space needed for the robots; once again saving money on valuable real estate costs. The common perception is that all robots are large, heavy and complicated. That is not necessarily the case with the advent of the more mobile and compact robots; when deployed strategically, the technology can deliver a big impact to a manufacturer’s bottom line. Smaller robots are able to maximise available pockets of space within the existing layout, hence increasing the viability of retrospective deployments. Size aside, the weight of the robot delivers benefits as well. The lightweight robots are easily mounted on walls or

moved from one location to another, adding flexibility to the manufacturing process. This is a advantage for when manufacturers need to expand, move or grow their manufacturing business.

Safety Economics Robot technology has evolved with the development and improvement in the understanding of the modern manufacturing workplace. Manufacturing workplace studies and enhancements in robot technology have created environments, today, where employees and robots coexist effectively and productively. Safety features, including sensors to detect an opposing force or obstruction in the robot’s field of operations, ensure that the robots function safely and efficiently without causing harm to humans. By doing the monotonous and in many cases, the heavy-lifting and potentially dangerous tasks, robots enhance the manufacturing workforce’s productivity while increasing manufacturing throughput. Instead of focusing on purchasing ‘cheap’ robots, thinking instead of value for money is pivotal to business growth in the long

Robots can be used for quality control and automating repetitive processes.

The robots can be operated and programmed remotely.

run. After-sales service, product support and training programmes are sometimes factored into the overall total cost of owning the robot. In that sense, paying more upfront could mean the absence of any hidden costs in the future. In a world where customer satisfaction is paramount, maintaining consistent precision is the key to success and growth. While business owners view technology investments in the immediate or short term, a more studied view will see them recognise value and payback, typically in 12 to 15 months.

Conclusion The speed at which a product goes out to market is a major concern for manufacturers. Being able to utilise people and technology both simultaneously and effectively is the key to success. Business owners must therefore be aware of exactly what they require in order to purchase and deploy a robot that is best-tailored to their operations. “The ideas presented here provide an alternative view to deploying robots that deliver the benefits without the technical and financial burden that usually accompany industrial robots,” concluded Enrico Krog Iversen, CEO, Universal Robots. ENQUIRY NO. 4201 June/July 2013 | industrial automation asia  23


issues & insights

The use of robots sets a benchmark in the manufacture of heavy-duty diesel engines in China. By Laura Schwarzbach, corporate communications, Kuka Roboter

Case Study:

Zero-Defect Assembly W

ith a yearly capacity of 125,000 units, a production plant in the Chinese district of Huishan is setting global standards for the manufacture of heavy-duty diesel engines. Robots from Augsburg, Germany, are being applied to a range of tasks in this plant. The highlight here includes the handling of 700 kg cylinder blocks by a KR 1,000 titan robot. The First Automobile Works (FAW) Group is one of the largest automotive manufacturers in China. In February 2012, FAW

24  industrial automation asia | June/July 2013

Jiefang Automotive Company Limited Wuxi Diesel Engine Works, a full subsidiary of the FAW Group Corporation, began operating a production plant for the manufacture of heavy-duty diesel engines in Huishan. With this investment, the brand continues to underscore its expertise in producing heavyduty trucks. At the same time, the Chinese internal combustion engine industry is equipped for global competition. From the beginning, the company wanted to set the

benchmark in the production of medium to heavy-duty commercial vehicles. Production is characterised by the manufacturing processes, production equipment and quality assurance measures. All lines stand out for their flexibility, efficiency, adapted d e g re e o f a u t o m a t i o n a n d continuous flow of information. Robots and machines for the assembly line are strictly selected according to the principle of ‘high reliability, high flexibility, high efficiency and high profitability’.


For the handling of the cylinder block, one robot can take the place of at least four rotary and lifting devices as well as all of the personnel,” says You Xuejun, chief planner for the project at Tianyong Mechatronics (Shanghai), the general contractor for the assembly line. The combination of a workpiece weighing between 500 and 700 kg and a 200 kg gripper means only a heavy-duty robot with a 1,000 kg payload capacity can be considered for this task. For this, the KR 1,000 titan was chosen. With a maximum reach of 3,202 mm, a repeatability of ±0.1 mm and a payload range of 1,000 kg. Its working space of up to 78 cu m also ideally fulfills the requirements for this application. Its performance corresponds to a medium-sized car.

Robots Applied To A Range Of Tasks

Handling Of Cylinder Blocks Weighing up to 700 kg, the need to rotate the cylinder block of a 6DM diesel engine (for example, for the assembly of a cylinder bank, crankshaft and oil pan) presents particular challenges on the assembly line. Conventional handling with rotary and lifting devices as well as adequate manpower was not possible due to space requirements and a lack of efficiency. “ I n o rd e r t o g u a r a n t e e production capacity and quality, robots had to perform this work.

Today, a total of five robots perform tasks on the diesel engine assembly line. Besides the KR 1,000 titan, two KR 16s are taking on sealing applications, while a KR 210 and a KR 500 are responsible for heavy handling and assembly operations. One example comes from the installation of flywheels: With a payload capacity of 210 kg and a reach of 2,700 mm, the six-axis KR 210 can position the flywheel in handshake mode without damaging any surfaces. The tasks of the KR 500 also include the precision assembly of the enormous crankshaft for the heavy-duty diesel engine. The KR 1,000 at the Xichai Huishan plant uses its size and performance exclusively to handle cylinder blocks from a special island station. As soon as the cylinder block, weighing 500 kg before assembly, reaches the work island, the robot picks it up under sensor control and sets

it down on a workpiece carrier. From here, the cylinder block passes through several work steps, including the installation of connecting rods, cylinders, oil pans, and so on. During this assembly work, the robot must rotate the cylinder block exactly 90 degrees at a defined point. Upon completion, the cylinder block — now weighing 700 kg — is brought back to the island station where the robot picks it up and performs a 180 deg rotation to set it down on the workpiece carrier. The block then continues its journey through the assembly line.

Efficient High-Volume Assembly “Particularly during the assembly of the flywheel and crankshaft, the utmost precision is required. The robots must install the heavy components, at times applying a great amount of force, while causing no damage to these important parts. Their masterful performance allows these machines to complete the challenging tasks. Using the robots has allowed us to achieve a high level of quality from the assembly line with a defect rate of zero,” says Mr You. The intelligent system layout with the island station (in a double-X design) allows for shorter paths within the complete assembly line, as such reducing the number of work carriers, increasing the efficiency of the assembly line and reducing the investment costs. Following a phase of optimisation, another superlative has been achieved: Today, the assembly line has a production output of 125,000 units a year, exceeding the 100,000 called for in the original planning. ENQUIRY NO. 4202 June/July 2013 | industrial automation asia  25


process control

‘Kinetic Rain’ is a dynamic sculpture located at Terminal One of Changi Airport in Singapore. This artwork’s implementation was aided by the technology of PC-based control. Contributed by David Chia, MD, Beckhoff Automation

Case Study:

A Symbiosis Of

Technology And Art W

hat is probably the world’s largest kinetic sculpture was realised in ‘Kinetic Rain’ at Terminal One of Changi Airport in Singapore. The artistic concept of the installation and the calculatory design of the choreography originate from the Berlin-based Art+Com. In allusion to the tropical rain, the installation consists of 1,216 sparkling, copper-plated aluminium droplets. These are suspended from the ceiling on

26  industrial automation asia | June/July 2013

thin steel wires and each one is moved by a small servomotor. During a 15-minute show, the droplets are formed into different pictures connected with the subject of flying. The challenge of moving 1,216 ser vo axes synchronously was solved on the basis of EtherCAT, TwinCAT and the compact Servo Drives in Bus Terminal format. “The harmonious interaction of more than a thousand droplets also symbolises the many people at the airport who ensure day

after day that passengers and visitors to Changi Airport are positively surprised and have fond memories of it,” says Yeo Kia Thye, vice director of Airport Operations at the Changi Airport Group. The installation, which consists of two contiguous fields of 608 droplets each, extends over a total area of more than 75 sq m and plays over a room height of over 7.3 m. The technical implementation of the overall project and the


During a 15-minute show, the 1,216 droplets are formed into 16 different pictures connected with the subject of flying.

adds Peter Haschkamp, likewise director of MKT.

How Do You Control 1,216 Axes Synchronously

Due to its very flat design, the C6525 Industrial PC is suited to installation in cramped spatial conditions. Thanks to an optional SSD storage medium and passive cooling technology, the C6525 does not contain any rotary components.

programming was accomplished by MKT from Olching, Germany. The company received support f ro m B e c k h o f f A u t o m a t i o n during the programming and implementation of the control system. “In ‘Kinetic Rain’ we have realised the most sophisticated project of this type to date,” says Axel Haschkamp, director of MKT, “More than 2,000 engineer hours flowed into this project. Particularly challenging was not least the transport of the fully preassembled installation weighing

30 tonnes to Singapore.” The demands on the control of ‘Kinetic Rain’ are very high, with the precise movement of 1,216 axes. In addition to that, the project demanded high availability, compact design of the components and the replacement of components without addressing. “One of the paramount specifications of our customer, Changi Airport, was that the system must run 24 hours a day. Even if an individual axis were to fail, the show must go on,”

“The synchronous movement of 1,216 axes is one of the absolute highlights of this project,” stresses Raphik Shahmirian from sales at the Beckhoff office in Munich, who attended to the technical implementation of the sculpture in close cooperation with MKT. Beyond that, requirements h a d t o b e m e t w h e re t h e dynamics, precision and speed of the motion sequences were concerned. The droplets move with a speed of 1.5 m/s and an acceleration of 1.4 m/s sq. The movement must be dynamic, but at the same time flowing and absolutely free of jerks. MKT found the solution to this task in the PC- and EtherCAT-based control platform with compact Servo Drive Technology. A central C6525 Industrial PC is responsible for the control. It June/July 2013 | industrial automation asia  27


process control

A Beckhoff C6525 Industrial PC with the TwinCAT NC PTP automation software is responsible for the central control of the 1,216 axes. Communication with the GUI computer from MKT takes place via ADS.

In the Beckhoff servo terminals, which fit into the EtherCAT terminal row, and the AM3121 compact servomotors, MKT found a compact drive solution that fits into the tight installation space in the ceiling of the airport terminal building.

communicates by TwinCAT ADS with the special GUI computer from MKT. At the same time, the PC centrally controls the 1,216 axes via TwinCAT NC PTP and acts as the master. Via the TwinCAT cam table function the master PC coordinates the distribution of 28  industrial automation asia | June/July 2013

the position data to the six slave PCs. Each of which 192 or 208 axes are assigned, and ensuring the synchronicity of all axes according to a master axis as a reference. Communication takes place in real-time over EtherCAT up to the drives.

The GUI computer serves for visualisation, but also contains the show in the form of a table containing the position data for each droplet at time intervals of 200 ms. This corresponds to five pictures per second. A flowing movement perceptible by the human eye without jerks is possible only through the interpolation in TwinCAT NC PTP. H e re , 1 0 0 i n t e r m e d i a t e positions are calculated for each droplet using a spline algorithm in a 2 ms NC task. These calculations take place on each slave PC for the local axes assigned to it. The artistic intention to have the synchronous movements of the droplets run like a kind of 3-D film is possible only through the use of EtherCAT and TwinCAT NC PTP. While the master keeps all the axes synchronous to one another, the slave PCs calculate the positions of the axes assigned to them every 2 ms and communicate them over EtherCAT in real-time to the Servo Drives.

Compact Servo Drive In A 12 mm Terminal The movement of the individual axes is precise and lies in the


range of 1 mm for an overall length of 7.6 m. The maximum offset between two droplets is 0.25 mm. Each droplet is controlled via an EL7201 EtherCAT servomotor terminal and a servomotor of the type AM3121. “In the servo terminals, which fit into the EtherCAT terminal ro w, w e f o u n d a c o m p a c t solution that fits the structural c o n d i t i o n s p e r f e c t l y, w i t h limited installation space in the ceiling of the building,” stresses Mr Haschkamp. In addition, servo drive technology offers dynamic advantages and allows flowing transitions.

Modularity Of The Controller Simplifies Commissioning “Important for us was also the modularity of the control solution

and the fact that an individual axis can be exchanged without addressing. That made partial commissioning possible, for example; we were able to work in parallel on software, hardware and the mechanism, allowing us to keep within the narrow timeframe that we had for this project,” says Mr Haschkamp. With TwinCAT NC PTP, it is additionally possible to ‘jog’ the whole show, ie: one can fast forward and rewind like a film. That very much simplified the commissioning for MKT. If an individual passage of the sequence was not yet 100 percent satisfactory, the engineers from the company could repeat it continuously. Mr Haschkamp adds: “With other solutions, this is not possible and you are forced

SENSORS SAFETY RFID Contrinex (S.E.A.) Pte Ltd

to continually start the show from the beginning each time until you reach the desired position, which is very time consuming.” In contrast to comparable kinetic sculptures realised by MKT in the past over decentralised hardware controllers, ‘Kinetic Rain’ is controlled via a central PC and software and transmitted over EtherCAT. The cam table function, which the company accommodated locally in the drive amplifier in earlier control solutions, is now executed by the software. In this way, the position data can be managed centrally and distributed in real-time to the axes over EtherCAT. ENQUIRY NO. 4301

Assembly Technology 2013 Bitec Bangkok, Thailand Booth V15 Hall 104 20 – 23 June 2013

MiniMini

ENQUIRY NO. 580

The smallest inductive Sensor in the world!

June/July 2013 | industrial automation asia  29


process control

In the German beverage industry, crates are checked for missing bottles before leaving the plant. A vision sensor detects small irregularities that would not have been detected with conventional photoelectric sensors. This ensures quality and reliability are maintained. By Andreas Biniasch, technical editor, ifm electronic

processes use diffuse reflection sensors arranged in a matrix to look at the caps of the bottles from the top. If a bottle is missing, no light is reflected back to the sensor. The sensor provides an error signal to the controller.

Control Using A 3D Sensor

Case Study:

Quality Control With 3D Vision

The company additionally uses the full crate inspection system from the OEM Recop. The heart of the system is the efector pmd3d from ifm electronic. This sensor is a 3D camera with integrated evaluation. Its resolution is 64 x 48 pixels. For each of the 3,072 pixels the sensor supplies a distance value, which is precise to the nearest millimetre up to 25 times per second. The device looks at the crate from the top. The distance between the bottle cap and the sensor is evaluated at defined positions in the camera image. If it is outside the set range, the sensor provides an error signal and the crate is rejected. One sensor alone can reliably detect several missing bottles.

Advantages Of The 3D Control

A

lot of glass is handled at Gerolsteiner Brunnen in the Eifel mountains. Every hour, up to 60,000 bottles are filled on each line. Numerous different sensors ensure that processes run smoothly. At the end of the production the ‘full crate control’ checks whether the crates are filled with the correct number of mineral water bottles. If a bottle is missing, the crate is rejected and the missing bottle added manually before the crate leaves the plant. Fortunately, a bottle found missing in a crate rarely happens. 30  industrial automation asia | June/July 2013

If it does, the reason for this is often the bottle packer. With its pneumatic grippers, it takes the bottles from the sorting system and puts them in the empty crates. When doing so, it is possible for a bottle to not be gripped correctly. Therefore a full crate inspection unit is installed on the conveyor belt. The optical 3D sensor looks at the crates from the top to check them for missing bottles before they are palletised and delivered.

Conventional Control For Missing Bottles Worldwide conventional bottling

Compared to the conventional crate monitoring using diffuse reflection sensors, the sensor can find additional faults in the crate. Due to the distance measurement which is precise to the nearest millimetre, it detects small differences in height. If, for example, broken pieces of glass are between the bottom of the crate and the bottle, the bottle would be slightly higher. This would be detected by the 3D sensor rejecting the crate. Photoelectric diffuse reflection sensors, however, would not detect this fault. In addition, the vision sensor can be set to different shapes of crates and bottles via software parameter setting. The reference image can be selected later on using


dark print, which again and again lead to faults with the diffuse reflection sensor method, is no problem for the 3D sensor. Since the 3D image is evaluated in the sensor, an external controller is not needed. The sensor’s switching output can trigger, via a switching signal, that crates with missing bottles are rejected.

Rejects At A Glance

Missing bottles are shown in red and statistically evaluated.

a simple switch.This eliminates the need for a mechanical modification of the reading matrix as would be necessary for the diffuse reflection sensor method. This saves time and money when the plant is retrofitted. The surface characteristics of the bottle caps, eg: silvery or matt

The company uses the Ethernet process interface of the sensor to visualise the test result on a touch panel display. The machine operator can read the distance values for every bottle in the crate. A statistics function enables to detect the faults over a defined period. Even the information which bottle positions often lead to faults can

be evaluated via a statistics. Therefore the machine operator can find and rectify machine parts which do not function properly. This analysis is useful especially when machines are set up.

Bottom Line Using the vision sensor, the company could enhance their full crate inspection system with additional diagnostic features. An adaptation to different geometrical shapes of the crates is done via the software, eliminating the need for a mechanical modification. Therefore the plant can be retrofitted much more easily and quickly. The sensor can also be integrated for quality control in other industrial areas. ENQUIRY NO. 4302

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June/July 2013 | industrial automation asia  31


software & Networks

The incorporation of visual data is taking embedded systems to new levels of performance. By Casey Weltzin, product marketing manager, National Instruments

T

he amount of information that our brains can interpret from visual data is astounding. We can identify objects, measure distances, and quickly make decisions on how to act and respond in different situations. Even unconsciously, we are constantly using visual information as feedback to control our own balance and movements. The same way that our brains can apply sophisticated algorithms to visual images and can give us an incredible understanding of the world around us, embedded systems everywhere are starting to use visual sensing as one of the primary means to acquire data and make intelligent decisions. Universities have been researching computer vision since the 1960s, but the intersection of several enabling technologies is catalysing an embedded vision revolution. Imaging sensors, processing technologies, and software algorithms are all contributing to a new generation of embedded systems. “The ability for machines to see and understand their environments promises to change the electronics industry. High-volume applications in automotive and consumer electronics are fueling innovation and driving down cost, which will ultimately help embedded vision to proliferate across a multitude of other markets,” commented Jeff Bier, president, Embedded Vision Alliance.

32  industrial automation asia | June/July 2013

High-Volume COTS Embedded Vision Technology Like many Commercial Off-The-Shelf (COTS) technologies, high-volume consumer electronics has pushed the boundaries of what is possible within the constraints of power, size, and cost. Tiny cameras are now standard features on laptops, tablets, and mobile phones, with millions of pixels packed into a few square millimetres. While the current size and capabilities of today’s image sensors are impressive, the biggest technological advancement in embedded vision has ultimately been the processing power. With the performance of processors doubling every two years and the continued focus on parallel processing technologies like multicore computer processing units, graphics processing units, and field-programmable gate arrays, embedded system designers can now apply sophisticated algorithms to visual data and create more intelligent systems. I n s t e a d o f re l y i n g o n l y o n m e c h a n i c a l measurements like temperature, sound, and vibration, embedded systems now also have access to visual information and enough processing power to immediately respond. The mass incorporation of cameras in computers, mobile phones, and automobiles can be witnessed by all. IMS Research estimates the

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Embedded Vision Technology


are incorporating embedded vision to increase the intelligence of their motion systems, which is leading to dramatic increases in manufacturing yields. Using image data, these machines can accurately determine the exact orientation of a chip and compensate for deviations. They can also use the same image to inspect for defects and reject parts long before the end of the line.

Life Sciences

The embedded vision market is expected to reach almost 700 million units by 2016.

five-year compounded annual growth rate of the embedded vision market to be 86 percent, reaching almost 700 million units by 2016. A good example of this growth is the Microsoft Kinect sensor, which became the fastest growing consumer electronics device in history. In addition, Samsung introduced its Smart TV with built-in features for facial and gesture recognition. It will not be long before cameras become a standard feature in refrigerators, microwaves, washing machines, and other everyday home appliances. This wave of adoption for embedded vision will continue permeating through all types of control and monitoring systems in industries such as manufacturing, life sciences, and transportation.

For life science applications, medical imaging is an area of much research and probably not the first thing that comes to mind when picturing small, low-power embedded systems. For over a century, different technologies have been used to develop noninvasive techniques for medical diagnosis and treatment. Whether it is X-rays, electromagnetic fields, or ultrasound, medical imaging typically involves a stimulus-response process and requires highpower systems for both signal generation and signal processing. Due to newer imaging sensors with higher resolutions and higher frame rates, passive imaging is developing into another approach to medical imaging, and is enabling smaller, lower cost devices that can be deployed in high volumes.

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ENQUIRY NO. 590

Machine vision in manufacturing has long been used in industrial automation systems to improve production quality and throughput by replacing the manual inspection traditionally conducted by humans. What is new is the integration of imaging technologies and motion systems to create higher performance manufacturing machines. Image data can now be processed fast enough to calculate motion setpoints, and machine builders are now considering ‘visual servoing’ as a new approach to increasing the performance of their automation machines. In semiconductor wafer processing, for example, a common source of quality issues is minor twists or offsets that occur as freshly cut chips are handled through the manufacturing process. New generations of wafer processing machines


software & Networks

Embedded vision technology has begun to penetrate the transport sector, reducing downtime, and improving overall safety.

concerns. Train operators have traditionally had to examine rail edges manually. New Vision Technologies in France developed an embedded vision system called Railshift that can continuously monitor over 30 m of rail and measure shifts in position within 5 mm. The company has installed over a dozen systems across the Paris Regional Express rail, which transports over three billion passengers every year and sends immediate alerts to rail operators when defects are detected. Vision technology is an important component in improving quality control within a production process. Another example of embedded vision in the railway industries is when the Siemens Rail Systems One example is the Nebula system created by Division in Colorado developed a transient recording Dr Jairaj Kumar and his colleagues at the Manipal system for the Denver light rail system. For years University in India to detect the development of foot the company’s engineers tried to capture and better ulcers in patients with diabetic neuropathy. They characterise the electrical arcing events that might used embedded vision to passively image patients’ occur if a sudden spike in voltage appeared on the feet while they stood barefoot on the glass base of power lines. Adding image data to the embedded the Nebula system. logging system the company implemented using Similarly, the research and development team CompactRIO hardware, from National Instruments, at Royal Philips Electronics developed image gave the company the insight it needed. processing algorithms that measured fluctuations in skin colour and correlated them to blood flow Cameras Everywhere through the body. Embedded vision technology in high-volume consumer applications is permeating all types Transportation of embedded systems. Sensors and processing The automotive industry began embracing embedded technologies are increasing in performance while vision by designing in driver assist features like reducing the constraints of size, power, and cost. backup cameras. Similar to consumer electronics, We have already started to see the proliferation the high-volume nature of automotive applications of imaging technologies in industries like industrial will ultimately make an impact on all types of automation, medical, and transportation, and it transportation applications. is only just the beginning. The creation of new In the railway industry, for example, the health markets and applications that we never thought of the rail is a constant concern, and any shifts in were possible will follow. position can lead to significant downtime and safety ENQUIRY NO. 4401 34  industrial automation asia | June/July 2013


instrumentation & Measurement

The Future Of

Smart ID

IAA spoke with Ram Ramaprasad, director of product management, Card Printing Solutions, and Dickson Chew, director for technical operations (Asia Pacific), Zebra Technologies, on the Smart ID market and the implications of Near Field Communication (NFC) for the industry. By Mark Johnston IAA: What is your outlook for the Smart ID market over the next 12 months? Ram Ramaprasad (RR): There is roughly about 6.2 billion cards that were shipped in 2011, and the expectation is that it is going to be close to double that at 11.1 billion by 2017. The associated revenue is about US$7.3 billion globally. From a growth perspective, t h e A s i a P a c i f i c re g i o n i s possibly leading that space. Looking at some of the major projects taking place in the government segment, it is in India and China, and the other Asia Pacific regions that are leading the way. We do not see as many other

projects in, for example, the US or Western Europe. Smar t card applications broadly fall into two categories. The first category is what we call the security part, which is fairly well established. An example would be your driver’s license card and the national ID cards. The second category that we are seeing more traction nowadays, especially in India and a lot of other places, is the e-governments. IAA: What is the growth like for a market such as Singapore? Dickson Chew (DC): We are currently deploying a loyalty card programme in Singapore that is applicable for e-payment.

RR: The other one that is fairly well known is the EZ Link card, which can also be used as a student card, and gives you access to a whole variety of services. Once again, you can categorise this under education, or the broad category of e-government. And again, these are smart cards, they have specific information to allow people to access those services. IAA: What about growth factors in new technologies like NFC? RR: From an overall perspective, as you know today, the Samsung phones are the ones that primarily have NFC support. Zebra has been quite active in that space, June/July 2013 | industrial automation asia  35


instrumentation & Measurement

IAA: Do you see NFC affecting your business, as in the developed world, it may be more convenient to use an app on your NFC enabled smartphone, rather than needing a separate access card? RR: Perhaps in the very long term. In the near term, some of the applications that will be affected are the simpler ones like the loyalty cards. It is hard to envision government related cards as applications on your phone, or thinking about having access control being only on the phone. This is due to two reasons; the first one, if you take a look at the entire population of the people who have access in this building, not everyone is going to have a smartphone. The second part is that cards will still be a complementary technology, because what happens when you lose battery or what happens in some buildings where the coverage is not very good? 36  industrial automation asia | June/July 2013

I think Hyatt announced recently in some hotels that you can actually get the keys and go straight to your rooms and use your phone to activate the locks. Sounds good, but it is a question of widespread deployment and what is the infrastructure that is needed and so on. IAA: What industry trends do you foresee over the next 5 to 10 years? RR: We were just having a discussion with our colleagues, and we realised it was not too long ago that you could hardly make out your face on these cards. This, of course, reflected the digital technology at that stage. Now, because of the improvement in the technology, you could say the pictures are almost picture perfect. The amount of data that can be stored on these cards is increasing, to the point now where I can actually store my medical data. At the moment, this is still difficult, but in the future it will become easier. Currently, time you can store some biometric data, but in limited capacity. Going forward it will be possible to store more information, like facial recognition and fingerprints, and as such, it will also increase the level of security access. I believe, the third and most important area will be where you are going to see the most significant change. This will be what is going to be driving the applications that are used for printing, creating or programming these cards. What I mean by that is that about five to six years back when I joined the company, card printing technology was essentially a PC that was connected to a printer. Since that time, it is becoming more and more like an enterprise deployment. The intelligence

Jenny Rollo, Sydney, Australia

in terms of getting ready for what we think is the opportunity. All of our printers today have an NFC tag on them. Our customers ask us questions like, for example, ‘how do we load cards’. As such, we have an application called print-touch, so essentially, if you have an NFC enabled phone, and if you take it near the NFC tag, it will automatically take you to the website that is associated with that particular printer. From there you can access videos on how to load the cards, and so on. We can actually encode NFC cards using our printers today. The basic encoding technology all stays the same, the only difference is the format of the data. We have an application that will allow you to format your data according to NFC standards.

Card printers produce access cards that are critical for today’s security conscious organisations.

within the devices are increasing, and you are starting to see iPads and other devices playing a part in the whole process. IAA: What are the major challenges in terms of security when it comes to access cards? RR: The first and foremost is in terms of fraudulent cards, which are cards that are produced by unauthorised people. We have made quite a bit of progress along the way. Among the things that we have done is to tag all our consumables, the ribbons, the laminates, and so on. They are all tagged with RFID chips. The second aspect from a security perspective is to embed more security features, because it is not about what is visible on the card. There are a lot of security features that are not visible to the eye and security features that are included in your chip. The third area is authentication. The printers will not print the card until you authenticate yourself to the printer. Therefore, when you present the smart card, you can also have a fingerprint scan to be validated. Security capabilities are going to be a continuous focus for improvement.


RR: In the last four years, we have transformed our product portfolio. The ZXP series 7 is now our flagship printer. So what is different about the ZXP series 7? I will categorise it into three categories. The first category is in terms of the operational effectiveness. Meaning that the product is fast, and can produce 300 cards when printing is confined to a single side. Our closest competitor prints at 220 cards. Also, if you are printing high security cards with lamination, we are twice as fast. The second category is better image quality, and the third category is the cost of ownership. Our lamination technology is the least expensive in the market. Also, as I mentioned earlier, we are looking at our printers as network devices capable of printing. As such, when you are deploying printers in multiple locations, you would want to be able to manage it as network devices. Enabling cloud printing is also an important issue. This would enable the customer to print without the use of any driver, from an Android or iOS device, for example.

We also put in a fair amount of investment, and we have a technical centre in Guangzhou, China, hiring about 100 people for various functions, like engineering and design. This is our biggest centre in APAC. We are also represented in Malaysia, Indonesia, Thailand, India,

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DC: Asia has been a high growth a re a f o r t h e c o m p a n y. We started off six years ago, with 60 employees, now we have about 300 in APAC. Zebra APAC represents about 15 percent of the company’s overall sales.

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IAA: Is the ZXP series 7 a global release? RR: Yes. We officially launched it in Paris France, and we have started shipping since February 2013. We have just started in Asia Pacific.

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June/July 2013 | industrial automation asia  37 FlukeHT-Magazine-IAA.indd 1

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instrumentation & Measurement

Plant safety can be improved by making available important information to the relevant crew members at the right time. Smart sensing in this regard can improve the situational awareness of plant staff and as such improve operational effectiveness and safety. By Jonas Berge, director of Applied Technology, Emerson Process Management

Situational Awareness

Smart Sensing:

W

e sometimes read about plant disasters in the news, and ever y so often the cause has been a manual valve which was believed to be closed but was actually open. The information did not get passed on to the new shift crew at the shift change. Had they known the valve was open, had they had that crucial piece of information, the disaster might not have happened. We tell ourselves ‘had I only known,’ and we also say hindsight is 20/20. WirelessHART technology provides a way to add important measurements and feedback to the operators to improve situational awareness. As such, enabling them to make better informed decisions based on actual information rather than having to deduce

38  industrial automation asia | June/July 2013

or infer information from other variables. Transmitters using this technology can easily be installed in older plants.

Heightened Situational Awareness IEC 62591 (WirelessHART) is the international standard for wireless in process applications. It is already being used in many maintenance-related application such as monitoring the health of heat exchangers, blowers, fin fan coolers, process pumps, valves, and other assets as well as reducing operator rounds. The standard is also used to help improve operations providing new visibility for operators. This will enable them to make process adjustments that can extend asset

life, reduce energy consumption, and improve personnel safety. For example, pump cavitation that goes unnoticed will lead to pump damage that causes unscheduled downtime and requires costly repair or replacement. Plant operators that are not aware when a pump is cavitating will not do anything about it. To avoid this problem, a pressure transmitter can be installed to measure pump discharge pressure. Essential a s s e t m o n i t o r i n g s o f t w a re calculates and monitors the standard deviation of this measurement to detect the early signs before pump cavitation. Additionally, a vibration transmitter with PeakVue vibration


acceleration detection is useful for isolating developing faults before there is any significant increase in overall vibration velocity. With a pump monitoring solution based on these tools, operators can get an early warning of the problem. This will enable them to make the necessary process adjustments to prevent problems from occurring, as such ensuring longer life of the pump and reduced downtime. Consider the case of fans used in cooling towers. In cases where excessive cooling tower capacity is available, it is sometimes possible to meet cooling demands even with one or more fans shutdown to reduce power consumption. However, operators are often reluctant to shut down fixed-speed fans because they have no visibility of how many of the cells are needed. Nor do they know what speed to set for the variable speed fans to provide sufficient cooling. In this situation, transmitters can be used to provide the inputs to essential asset management software that analyses the cooling tower efficiency. It also gives the operators visibility of the cooling efficiency and heat load on the cells. Software will suggest which fixed speed fans operators

WirelessHART vibration transmitter.

can shut down, or the optimal speed setting to balance the load across variable speed fans. The objective is to provide sufficient cooling while minimising power consumption, as such reducing energy cost. A third example relates to personnel safety. In the event chemicals splash onto a person in the field, the worker will seek one of the safety shower and eyewash stations. The person may not be able to radio for help at the same time. As such other personnel are unaware and cannot come to the person’s assistance. By fitting discrete transmitters onto the safety shower and eyewash stations, operators in the control room can be made aware as soon as the stations are activated. They can then call on first responders to assist the person in distress, as such reducing the time to respond. Fourth, remote sites such as unmanned offshore platforms or well pads often have no monitoring or automation for the well heads because no power is available at site. Therefore, operators at central operations do not know which wells are producing and which ones are not without traveling to the remote locations. This happens very infrequently because of the time, cost, and sometimes hazards involved in making such a trip. Similarly, operators of sites with injection wells for water and chemicals or gas lift and water wash for Enhanced Oil Recovery (EOR) typically have no visibility into how much injection is increasing production. They can therefore cannot optimise the injection process to improve results and reduce costs. However, installing pressure, d i f f e re n t i a l p re s s u re , a n d temperature transmitters on each wellhead can enable operators to monitor production and injection

from a central location. Awareness of which wells are producing and which ones are not, and how the production changes as a result of injections, allows optimisation of production and reduction of cost. Several other measurements are possible, such as choke valve position or well casing pressure to detect leaks as well as monitoring of separators and storage tanks. Finally, operators typically cannot be sure of the actual position of manual valves without going to the field to verify if the valve is opened or closed. An experienced operator can sometimes tell from other process measurements whether a valve is opened or closed, but an inexperienced operator may not. Occasionally mistakes or accidents may happen because some valve is in the wrong position. But by mounting position feedback transmitters on important valves, actual position feedback can be provided to the operators so they can know for sure what the position is. I n s h o r t , Wi re l e s s H A RT technology offers a number of ways to increase situational awareness so that operators can make more-informed decisions.

Fits On Any System Gaining these benefits of WirelessHART typically involves integrating the information they provide with control systems. That is especially true in largescale plants and fields that can approach 1,000 wireless transmitters. But what if the existing control system does not offer native WirelessHART support? It still makes sense to manage these smart sensors plant-wide from intelligent device management software in an asset management system. How can users get the information to where it is needed for that to happen? June/July 2013 | industrial automation asia  39


instrumentation & Measurement

card. Multiple gateways can be connected to the same Ethernet for plant-wide applications. For instance, they can interface to systems supporting the Modbus/ TCP protocol. This is the most common way on modern control systems. The Ethernet ports on the gateway can also be used to interface to systems supporting the EtherNet/IP protocol, for instance some PLCs. OPC-DA is a third protocol option. OPC is a protocol between software applications. OPC proxy/ server software on a workstation communicates with the gateway and makes data available to any OPC-DA clients such as HMI software or a system database.

Intelligent Device Management Integration

WirelessHART discrete transmitters on safety shower and eyewash station.

Fortunately, Modbus/RTU, Modbus/TCP, OPC, and the HARTIP protocol can enable integration of process variables. They can also enable all setup and diagnostics information from WirelessHART transmitters into any system.

Process Variable Integration Process variables from the transmitters can be used in control systems like a Distributed Control System (DCS), Programmable Logic Controller (PLC), or Remote Terminal Unit (RTU). They can also be used directly in software such as a Human Machine Interface (HMI) or for asset monitoring, machinery health monitoring, or a historian. Since there are many ways to get process variable data from the gateway, no system is too old to accept such data. 40  industrial automation asia | June/July 2013

One method is to use RS485 network cabling to integrate the gateways with a host system having a serial interface card that supports the Modbus/RTU protocol. Multiple gateways can be connected to the same RS485 network for plant-wide applications. This is the most common way to bring in the standards signals on older control systems. The process variables and status desired from each transmitter are selected in the gateway. Import and export functions enable faster bulk edit and faster system configuration. Ethernet provides a second option. It supports multiple protocols in parallel on the same port for integration of the gateways with host systems having an Ethernet interface

The transmitters can be managed from intelligent device management software for daily maintenance and turnaround planning. There are two aspects to doing this: Getting the information from the device to the software, and then displaying or using the information (especially if devices are from different manufacturers) within the software. The same handheld field communicator used for 4-20 m A / H A RT a n d F o u n d a t i o n fieldbus devices can be used to configure and check the health of transmitters. But for installations with lots of transmitters, centralised monitoring is more practical. Modbus, EtherNet/ IP, and OPC-DA are suited for p ro c e s s v a r i a b l e s , b u t d o not support intelligent device management software. The HART-IP protocol provides the ability to access all the configuration and diagnostics information in the transmitters, beyond the process variable, from intelligent device management software on third-party systems.


The HART-IP protocol uses the same Ethernet cable as Modbus/ TCP, EtherNet/IP, and OPC-DA. It also uses the same standard commands as 4-20 mA/HART and WirelessHART and therefore requires no data mapping in the gateway or in the software. This makes it easy to manage the vast amount of configuration settings even for huge numbers of transmitters. T h e re a re t w o w a y s t o graphically display device setup and diagnostics data in the intelligent device management software: Electronic Device Description Language (EDDL) and Field Device Tool/Device Type Manager (FDT/DTM). For IDM software based on the EDDL device integration technology, the EDDL file for each device type is simply loaded. It therefore enables the IDM software to access all the information in the transmitters t h ro u g h t h e g a t e w a y o v e r HART-IP. For IDM software based on FDT/DTM device integration technology, a commDTM and gatewayDTM can be installed for the gateway as well as a deviceDTM for each device type. As such, it enables the IDM software to access all the information in the transmitters t h ro u g h t h e g a t e w a y o v e r HART-IP.

WirelessHART are still able to benefit from the capabilities that this technology brings. The result is lower maintenance cost, energy savings and increased production. A good way to start modernising the plant is by conducting an

audit of the plant assets and current work practices to identify the opportunities where asset and process monitoring should be added. ENQUIRY NO. 4502

Transmitters for flow, level, valve position, pH, conductivity, vibration, temperature, pressure, and acoustic as well as level switch and input for on/off contacts are now available to provide operators with visibility where there was none before. These are usually applications beyond the P&ID. Thanks to WirelessHART gateways, plants with systems lacking native suppor t for

ENQUIRY NO. 583

Putting The Technology To Work

June/July 2013 | industrial automation asia  41


instrumentation & Measurement

The technologies packed into a small sensor can result in big performances. By Joson Ng

A Sense Of

Things To Come? Derek Chua (L) and Albert van Wyk

I

t is amazing how much technology can be packed into a small sensor that is no bigger than 12 mm in length. The business of miniaturisation is a key to success today where many devices, either consumer or industrial, are getting smaller. This insatiable drive or affection for anything small has pushed engineering and research endeavours to a new level, a level that can only be reached with a fair amount of commitment and resources. A manufacturer of inductive and photoelectric sensors, Contrinex is a Swiss company that takes the sensor business seriously. Along with other technologies, they are able to offer a range of sensing solutions that stretches from entry level to the very high end products. The ability to serve the high end market stems from the investments poured into R&D, which range from 15 to 20 percent of the company’s yearly turnover, according to Albert van Wyk, global key account manager of Contrinex.

New In Singapore At the MTA 2013 show in Singapore, IAA spoke with 42  industrial automation asia | June/July 2013

Mr van Wyk and Derek Chua, regional sales and marketing manager in charge of Southeast Asia. The pair told IAA that their main draw at the show is the mini sensor DW-AS-623-03-963 and the Inox series 700 full metal housing sensor. It is hardly surprising that the spotlight is on those two products, because they can both claim to be breakthroughs in technology. “This miniature sensor (Mini) is currently the world’s smallest sensor. It has a diameter of 3 mm with a housing length size of 12 mm,” said Mr Chua. The main area of application is when there are space constraints. While size is a main factor for the Mini, the durability of the full metal housing sensor is its main draw. Mr Chua said: “As the housing is full metal, it gives a degree of robustness whereby the sensor is almost indestructible. The stainless steel housing is made from a single piece of metal, which gives good protection against knocks.” Quantifying what Mr Chua said, Mr van Wyk added: “Some 80 percent of failures in sensors are due to mechanical damage. We have customers who


manufacturing sector. We will also be looking at Indonesia, for it is a large market,” he said. Emphasising that, Mr van Wyk said he wants the company to be known as one that can serve the sector across all technology levels. He said: “We do not want to be known as a sensor manufacturer that only produces special sensor. With our technology transfers, our standard sensor can have features from the high end model, but at normal cost.”

Technology Trends

used to replace sensors every one to two weeks. After installing this, they went on for 18 months without any failure.” Although increasing product life significantly can in a perverse way hurt business, Mr Chua prefers to see things differently. He said: “When customers are using a reliable product, it gives them assurance. As such, they might change their other sensors into our sensors.”

Technology Within The Housing There is no doubt the durability of the sensor is impressive, the mechanism that allows this durability is arguably even more so. Mr van Wyk explained: “Induction sensors are made to sense metal. Because of the housing, our technology has to ‘see’ through the metal housing. We have a patented technology that uses an oscillator, which in turn produces a pulse. We send a current impulse into a coil and generate magnetic field and voltage. The pulse (when reaching the target) will generate eddy current. As you switch off the signal, the eddy current in the target dies off and it sends a pulse back into the sensor, and now, the coil is acting as a receiver. The difference between the voltages can be interpreted as the signal. This is the main mechanism of how the sensor works, also known as Condet technology.”

Business Plans In SEA Mr Chua intends to take on the diverse Southeast Asian markets with the company’s range of products. For a start, he highlighted the importance of brand awareness. “In Southeast Asia, we plan to create brand awareness. As such, we need to do a lot of marketing activities through our sales people and participating in key exhibitions. In the next one to two years, we will focus on Thailand because of her automotive industry and the mature state of the country’s

Looking into the future, IAA asked both Mr Chua and Mr van Wyk how they see the sensor market evolving in the next five years. Mr Chua felt that miniaturisation is still going to be dominating R&D efforts in this sector. He said: “Our product is related to what the end users are expecting of a device. As devices are getting more compact and the tolerances get tighter, so too must sensors. They will get smaller and smaller, but at the same time, they will give more and more. We can expect more things in smaller sizes.” Agreeing with Mr Chua, Mr van Wyk added that more functionality will be included in sensors. ENQUIRY NO. 4503 SG_IAA Magazine_83x110_V02_Layout 1 10.05.13 14:35 Seite 1

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June/July 2013 | industrial automation asia  43

ENQUIRY NO. 591

A test was conducted to illustrate the durability of the sensor.


energy

Asian Expansion IAA spoke with Francis Cheng, GM for Industrial Automation, Mitsubishi Electric Asia, on the market potential in Asia, and the company’s new development centre in India. By Mark Johnston IAA: What would be your biggest market in Malaysia? Francis Cheng (FC): Our biggest market in Malaysia is still Factory Automation, of which we are one of the top three suppliers of automation products in the countr y. The company does not distinguish whether the automation product is a PLC,

Servo, Motion System, or Inverter. Also, we are more competitive on the PLC level of automation products, rather than the DCS. The company has been gaining market share for the past three years. Of course, we hope to continue to gain market share and to achieve the number one or two position within the Malaysian market in the next two to three years. IAA: I hear d r ecently you opened a factory automation centre in India, could you tell me about that? FC: We established the Indian Development Centre (IDC). Outside of Japan we have the North American Development

Centre (NADC), so they are doing all the development works, and taking care of the requirements and needs in the Americas. We have another software development centre in Europe, we call it the European Development Centre (EDC), so now we have one in India, we call it the IDC. The Indian market is very big, so the IDC will have to support the whole region of India. For the Europe side, we cover Western, Eastern, and Central, all by the EDC. NADC is North America, we cover all of North America, all the way down to Latin America. IAA: How does the ASEAN market compare to other markets? FC: ASEAN is very important right now, everyone is focused on Asia. If you look at Asia, the major growth for the last two years is actually in China, and India. If you look at the GDP growth, there is steady growth in Asian countries, people still believe that ASEAN will contribute more. ASEAN means Southeast Asia,

CC-Link Energy Management Capabilities CC-Link, the open automation network technology, now comes equipped with energy management capabilities, creating a combined energy and production management control system. CC-Link IE Energy, as it is called, has capabilities to allow managers to monitor energy consumption by individual machines or processes over the same networks they are already using for general control purposes. Energy management has become an important issue for most organisations, particularly manufacturing companies whose energy consumption is usually going to be higher than that of non-manufacturers. A manufacturing plant will include many energy consuming devices, many of which are large electrical loads, such as ovens, conveyors or other heavy mechanical systems, all of which must work in unison to complete the production process. CC-Link IE Energy offers the ability to monitor all of these individually and in real time, allowing optimisation of each device to be achieved. ENQUIRY NO. 4602

44  industrial automation asia | June/July 2013


IAA: Are you pushing CC-Link more in the Asia region? FC: For marketing we have put CCLink as a separate product entity. We do not want to put it under Mitsubishi. We emphasis a lot on the open protocol, as such, any of the vendors or even any of our competitors can use the network.

Best in class!

side is still developing. Other countries, like Vietnam and Myanmar, I would say they are still developing because they are still very young. Whereas Laos and Cambodia will probably take another 10 years until they reach the same level as Vietnam and Myanmar.

IAA: Did you initially develop the technology with the intention to open it up? FC: Yes, of course, but again whoever knows the automation market very well they will know that CC-Link actually belongs to Mitsubishi. The same goes for Profinet/Profibus that belongs to Siemens, and DeviceNet, which belongs to Rockwell.

ENQUIRY NO. 4601

Best in class!

IAA: Do you see the market improving? FC: In the ASEAN region, the Factory Automation market will be growing, at least 20 percent, especially in Indonesia and Malaysia. Growth is also seen in Thailand, but Thailand is more for the carmakers. Indonesia would also be more carmakers and a lot of other general industry, such as textile, packaging, oil & gas, mining, and so on. They have huge resources, very similar to Malaysia, and I will stress again, Indonesian business, and Malaysian business is very important for our company. IAA: What is your definition of an emerging market? FC: I would say countries like Indonesia. The Malaysian side I would say that probably in West Malaysia, so the East Malaysian

Though Vietnam right now has a lot of problems, because of the currency depreciations, the inflation rate is high, and because the bank interest loan is high. A lot of local Vietnam companies are therefore closing up.

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plus IndoChina. IndoChina means all those countries like Laos, Cambodia, Vietnam, and Myanmar, for example. Southeast Asian countries are still very strong, so we have high expectations to increase our sales volume there.

23.05.13 08:06

23.05.13 08:06

June/July 2013 | industrial automation asia  45


sector spotlight

Improving Quality Through Automation

Case Study:

Improving water quality, and leak detection while increasing energy savings are some of the outcomes of a Swedish energy company upgrading its control infrastructure. By Lars-Goran Dybeck, owner, Blyerts

M

ä l a re n e rg i i s a n energy company active in the Mälardalen region of central Sweden. The company’s primary mission in the region is to provide electric power, district heating/cooling, broadband, sewage and water solutions. The company now has full control over both water p ro d u c t i o n a n d w a t e r quality due to an ABB control and monitoring system. This system is also designed to prevent energy thieves from stealing their profits.

Installation During Full Operation The water supply network has a total length of 600 km and every second, the company purifies 450 litres of water and pumps it to kitchens, bathrooms and 46  industrial automation asia | June/July 2013


Catching Energy Thieves The project also focused on improving energy efficiency and catching energy thieves along the 600-km long supply network. “A huge amount of pumping is needed to drive all the water through the network, and electricity is a

major cost,” says Pernilla Widén, head of Mälarenergi’s water treatment plant. Previously, the pumps were either on or off. Today they are constantly in action, but at exactly the right speed. “We have a range of pump sizes, and the monitoring

ENQUIRY NO. 584

garden houses around the city of Västerås. The wastewater then proceeds to its treatment plant before returning to the environment. The control and monitoring system now used by the company is based on ABB’s 800xA. “When we started looking at acquiring a new control and monitoring system, the old one was really on its last leg. It was vulnerable to breakdown and difficult to manage, and after careful analysis we decided to replace the entire system,” commented Göran Vikergård, responsible for tap water production at Mälarenergi. The whole installation was carried out while maintaining full operation — the company could not simply switch off Västerås’ water supply. For this reason, the energy consultants at FVB who designed and delivered the new system created a detailed action plan. “As expected, the whole re p l a c e m e n t p ro c e s s w e n t according to plan. One of the great advantages of AC 800M is the ability to simulate and test software codes to ensure that everything works as planned before closing an old system,” said Per-Arne Ekman, account manager at ABB. Different software that c o m m u n i c a t e s i n d i f f e re n t languages has been replaced with a single software that speaks one common language. “This means that we can keep track of the entire water treatment process from water supply via the pumping stations and on to the water purification plant. Instead of spending time on maintenance and being dependent on stocks of old spare parts, we can now concentrate on fine-tuning the installation and providing even better and more consistent water quality,” says Mr Vikergård.

June/July 2013 | industrial automation asia  47


sector spotlight

Mälarenergi’s water treatment plant has two operator workstations and one engineering station. There is a 55-inch screen in the control room that displays trends to give an accessible and quick overview.

system, together with variable speed drives, ensures that the right pumps always work at the right speed,” she adds. Variable speed pumps not only save electricity costs but also maintenance costs since they are subjected to less wear. The company expects to save approximately US$30,000 per pump each year, and the whole investment will pay for itself in as little as two or three years.

goal is 20 percent.” The company’s investment has also improved water quality. “We can, for example, minimise the use of additives. By having complete insight into the amount of additives used, we can constantly optimise the process to achieve the best water quality. This not only saves us money, but it is also better for the environment,” adds Mr Vikergård.

Faster Leak Detection Increases Revenues

The second step of the upgrade is to switch from the former operator environment to 800xA. The company gains in terms of visibility, efficiency and collaboration. It is possible to employ different alarm limits and use these in order to intervene before the situation becomes critical. Operators are able to prioritise and work more actively with issue prevention. This is the key to important savings linked to leak detection. Another advantage is easy visualisation of trends as well as logging more objects directly in the operator environment, which gives a better overview of the situation in the process. Long-

Before the upgrade the water supply network lost more than 30 percent of its water due to leakage. What has happened now, is the ability to detect water leaks has rapidly improved, as Mr Vikergård explains: “A 600-km long water-tight seal is almost impossible to achieve; we always have to live with some leaks. Now that we have new water meters and pressure gauges throughout the whole grid, we can locate leaks more quickly and act accordingly. Previously, about one third of the water we produced disappeared, which meant that we could not charge for it. Now our 48  industrial automation asia | June/July 2013

More Effective Operations

“We keep track of the entire water treatment process from water supply via the pumping stations and on to the water purification plant,” - Göran Vikergård, Mälarenergi term storage takes place in the Power Generation Information Manager, which facilitates support at every level in the organisation. Important data is readily available throughout the organisation, and improved quality and efficiency are achieved through collaboration.

In Summary Västerås and its surrounding areas consume 42 million litres of water every day, year-round. Thanks to a the control and monitoring system now implemented at the plant, the production facilities at the company now have full control over water quality and can also keep a strict eye on energy consumption as well as more rapidly detect water leaks. The benefits to this project include Improved water quality while reducing the use of additives, and rapid detection of water leaks. Also, the monitoring system together with new variable speed drives ensures that the water pumps always work at the right speed, which results in energy consumption savings and less wear on the pump. ENQUIRY NO. 4701


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ENQUIRY NO. 582


features

IAA At MTA 2013

IAA caught up with Jackson Chew, territory manager of igus Singapore at MTA 2013 to talk about the company’s new products at the show, as well as its plans for the ASEAN region. By Joson Ng

A

trip to igus’ booth transports the visitor to a world of chain systems and bearings. Surrounded by constant movements, the feel of being in an automated world is a very real one. Contributing to this backdrop are two products making their debuts in Singapore. They are the Rx series tube chain and the Twister Band according to Mr Chew. IAA understands that the tube chain can achieve an IP 40 rating, which is a rating system that provides a means of classifying t h e d e g re e s o f p ro t e c t i o n from solid objects and liquids afforded by electrical equipment and enclosures. Describing it as a “breakthrough in design,” Mr Chew revealed that the tube chain can prevent chips or sawdusts from entering, offering good protection and also opening up new opportunities. He said: “Most of the time, the chain system has to be designed on the outside of the machine, so for this (product), there is no concern even if they decide to put 50  industrial automation asia | June/July 2013

it inside (the machine).” Another breakthrough, according to Mr Chew, is the Twister Band. It is a chain that moves in a rotational direction. Apart from being impressive to look at, the movement provides a tangible advantage as well. He said: “This chain can move in rotation while keeping the bending radius, that means protecting the cable or hose inside.” The recent products are the results of hard work by the R&D engineers over at the laboratories. IAA understands that the company carries out 2,000 e-chains test and 5,000 chainflex test. The tests cover areas like life time, noise level, oil resistance, extreme temperature, UV resistance and many more. The company also launched 1 34 ne w pro du ct s a t Hannover Messe in April. Two products at the fair were the lubricant-free drylin E drive technology including motor and the modular igus e-spool from

stock. The former is applicable in the areas of medical devices, packaging technology and lab engineering. The manufacturer said the stroke length has increased by up to 63 mm and the ratio between effective length to total length has been optimised. The latter offers space-saving capabilities because the energy chain is rolled up in the home position, keeping paths free of obstructions. There is also no strain load on the cables. Finally, in terms of expansion plans in Asia, Mr Chew said his company is growing and a lot of that growth can be attributed to a solid foundation and out of the box thinking. As such, he is confident that the growth will continue. ENQUIRY NO. 4801

Jackson Chew


Q&A With Epson

Jessica Kwan & Edwin Lee

Jessica Kwan, assistant sales manager (Factory Automation System) of Epson Singapore told IAA what is new in the world of robot arms. IAA: What are your new products at MTA 2013? Jessica Kwan (JK): At MTA 2013, we showed our C4 series six-axis robots that are able to handle a higher payload of 4 kg. They come with two arm lengths: 600 and 900 mm. The long arm model is slimmer and weighs lighter as compared to the existing model. This C4 series is paired with the Epson RC700 controller, which offers our customers a choice of controlling the robots via a PC or PC-based controller. Also, this series of robots have articulated arms that are able to access hard to reach angles (eg: machine tending). So, they are suitable for industries like automotive and textile where they can carry out contour cutting.

Another trend we are observing is the adoption of robots for higher risk operations as business owners grow increasingly aware of workplace safety, and want to achieve high productivity while meeting safety regulations. In this regard, robots are now performing an increasing number of dangerous tasks that were once done by human workers, such as handling metal stamped parts or toxic materials, cleaning and polishing processes, machine tending, etc. Lastly, the increasing cost of land in Asia — especially in Singapore — has seen businesses demand greater space efficiency for their operations. In this regard, our smaller sized robots continue to be the choice as they offer no compromise in speed, reach, movement, payload, and cycle time, despite being able to operate in confined environments. ENQUIRY NO. 4802

IAA: Is speed the main advantage of SCARA robots? What other advantages are there? JK: Although speed is important, it is meaningless unless it is properly controlled for precise operations. So our SCARA robots also feature Epson Smart Motion Control Technology which enables them to achieve high accuracy and low vibration to match their high speed. IAA: What are the main business and technological trends in your field in the next two years? JK: Businesses are demanding m o re p ro d u c t i v i t y t o f e e d increasing demands, therefore we predict higher levels of automation requiring robots in manufacturing in the coming few years. June/July 2013 | industrial automation asia  51


features

Q&A With Hexagon Metrology

is targeted on specific markets, so events like seminars and workshops will be effective. LBC: In APAC, we see mixed signals. Some places have been difficult in the first quarter but we met our numbers. We think if we use the right strategy, we can still maintain our growth. So far, we are okay.

Leong Kim Huat (L) & Lim Boon Choon

IAA caught up with Lim Boon Choon, VP, APAC & Leong Kim Huat, GM, Hexagon Metrology Asia Pacific, to better understand their operations in Southeast Asia.

IAA: Your company recently moved into a larger office in Singapore. Tell us the reason behind this relocation and expansion exercise. Lim Boon Choon (LBC): Asia Pacific is a very important region to us. Although we have done very well in China, we can see more investments coming into Southeast Asia. For example, Thailand has traditionally been doing well over the last 10 years, particularly in the automotive sector. Now, we are also seeing Indonesia getting more interesting. On the Singapore and Malaysia front, the aerospace industries are growing. This is a market important to us and we want to capture 52  industrial automation asia | June/July 2013

it. As such, we are exhibiting more machines in our Singapore showroom. In addition, we have added an (measuring) arms calibration centre (in Singapore). Finally, we are looking at more collaboration with institutions. IAA: What is the business trend in Singapore and the rest of Asia Pacific for the rest of 2013 and early 2014? Leong Kim Huat (LKH): I think a lot of industries have gone out of Singapore. A lot of factories have migrated to Malaysia, Indonesia and Thailand. However, we still see high end products (manufacturing) remaining in Singapore. Our marketing strategy

IAA: You mentioned Indonesia as interesting. How do you assess the Indonesian market and what are your plans there? LBC: We have always been interested in Indonesia. The automotive sector there is growing fast. Of course, we also serve the aerospace and oil & gas industries of Indonesia. So far, we have been working through distributors. But now, we feel it is a good time to put in more investments. As such, we intend to open our own office and showroom there before the end of the year. We are actively working on this. IAA: How do you compete against Japanese metrology solutions provider in the Indonesia market, taking into account that a good number of automobile manufacturers there are Japanese as well? LBC: We have good relationships and experiences with several Japanese customers. In addition, we have solutions that are quite differentiated. We will continue in that line. I know Japanese metrology companies have a good local presence and good relationships with Japanese companies there, but I think Japanese companies are beginning to be more open. Over the years, if they find a technology provider where the quality and service are good, they are willing to consider. ENQUIRY NO. 4803


ASIA 2013

ENQUIRY NO. 586


features

Three facets of Programmable Logic Controller (PLC) network optimisation can ensure network availability, simplify network monitoring and configuration, and maximise network flexibility. By Gary Chang, product manager, and Mark Wu, technical writer, Moxa

E

arly automation systems were isolated and generally consisted of I/O devices connected directly to PLCs, which then connect to Supervisory Control And Data Acquisition (SCADA) systems in local control rooms. Today, a major difference exists in the architecture of modern industrial automation networks, a technology that is increasingly being deployed to connect large-scale distributed systems with remote monitoring/ control centres. That technology is industrial Ethernet. Industrial Ethernet technology consists of various Ethernetbased protocols, developed with deterministic capabilities a s ro b u s t a l t e r n a t i v e s t o costly proprietary automation systems. More importantly, the 54  industrial automation asia | June/July 2013

technology enables a scalable and unified infrastructure to converge all network nodes at the administrative, control, and field levels. Many advanced industrial automation systems have deployed gateways to efficiently bridge fieldbus I/O devices to Ethernet based PLCs, switches to connect PLCs and SCADA terminals at remote control centres. The purpose of this is to reduce operating costs and improve production efficiency of expanding automation networks. According to studies conducted by IMS Research, three of the most pervasive Ethernetbased protocols, EtherNet/ IP, Profinet, and Modbus TCP, account for more than 65 percent of the world’s existing industrial

automation deployments, and their collective growth from 2010 to 2015 is expected to exceed 18 million new nodes. However, the worldwide number of existing fieldbus devices (all protocols) will increase from 183 million in 2010 to over 326 million by 2015.

Worldwide market share by protocol.

Paul Pasieczny, Lublin, Kleeberga, Poland

Optimising PLC Network Performance And Management


This steady growth, despite the increasing popularity of industrial Ethernet, is primarily due to the fact that fieldbus is still considered as the easier, and more cost-effective, protocol to deploy at field-level networks than industrial Ethernet. Another contributing factor is that there are exponentially more nodes at field-level networks than nodes at control/supervisory-level networks. As growing industrial automation networks expand to increase productivity and factory systems converge for centralised control, the integration of various Ethernet-based protocols and bridging of fieldbus systems will be inevitable. An Ethernet-based singlenetwork infrastructure offers operators the efficiency of

centralised network management with greater network scalability and flexibility, higher bandwidth availability, and faster failure recovery. To o p t i m i s e s y s t e m p e r f o r m a n c e a n d i m p ro v e network manageability, switches and gateways should integrate seamlessly with industrial automation networks for centralised SCADA control and monitoring. However, integrating industrial fieldbus with industrial Ethernet presents integrators and engineers with two challenges: • Centralised monitoring of all network nodes, including switches, should be available on SCADA systems. However, standard industrial Ethernet switches do not process

industrial automation protocols and therefore are unable to be monitored on the same SCADA as the PLC and other I/O devices. • Existing fieldbus devices can account for a substantial portion of a company’s assets, and their integration with industrial Ethernet networks can be done via PLC modules. However, for large-scale control systems, deploying industrial Ethernet gateways would be a more cost-effective solution to integrate fieldbus devices. Although, a substantial amount of time can be required to manually configure the switches and gateways. Many manufacturers offer switches and gateways to

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June/July 2013 | industrial automation asia  55


features

integrate fieldbus-to-Ethernet communication for automation systems consolidation, with emphasis on device features and system interoperability between components and PLCs. But these are just the basic requirements of systems convergence. Most industrial switches and gateways available today are designed only with automationcentric perspectives. The optimisation of the PLC network, such as overall performance, configuration/management efficiency, and application flexibility, seems to have been overlooked.

Components For PLC Network Optimisation As device networks expand into larger control networks through fieldbus-to-Ethernet integration, network deployment and management become more complex. As such, network performance becomes highly critical. To optimise PLC network performance and management, industrial Ethernet switches and gateways should be designed with a network-centric approach. The purpose being to enhance overall performance, improve configuration efficiency, simplify network management, and provide application flexibility.

High Network Capability Assurance Performance optimisation of industrial automation networks is critical for maximum productivity and reliability. High bandwidth, high data transmission rates, switch Application-Specific Integrated Circuits (ASICs), and hardware features are indispensable components of high network performance. However, these factors are useless if the network is unavailable. Maintaining high network availability not only requires 56  industrial automation asia | June/July 2013

reliable network devices, but also speedy recovery of the network and its components during maintenance, or in the event of a connection/device failure. Industrial Ethernet Switches • High-Speed Redundancy Redundancy is a musthave component to ensure industrial automation reliability. Prolonged periods of unplanned system downtime can jeopardise onsite personnel safety, severely impact plant productivity, and possibly damage expensive factory equipment and machinery. Recent refinements in redundancy technologies not only provide millisecond-level network recovery, they can also substantially reduce costs for deployment. • Faster-Than-PLC Power Cycling Power cycling of switches and PLCs is generally required for plant-wide maintenance updates. Most managed switches can take approximately three minutes, if not more, to reboot because they have relatively low processing power. PLCs, on the other hand, operate by using simple ladder logic and power cycling normally takes less than a minute. Administrative-level nodes (such as SCADA and Human–Machine Inter face (HMI)) will have no access to control-level and device-level nodes until switches have completed Power-On SelfTest (POST) diagnostics and the bootstrap loading process. The difference between the duration of power cycling times of PLCs and switches will not only delay maintenance efforts, it can even cause port lockouts in some older time-sensitive automation systems. Advanced managed switches are now capable of

An oil packaging system is one application where the three components of PLC network optimisation are put to use, ie: high network capability, configuration/management efficiency, and application flexibility.

completing a power cycle in the 10s range. Industrial Ethernet Gateways • Processing Power Typical gateways have access to 16-bit processing power, which limits the gateway to eight simultaneous connections and delays response times. Newly developed 32-bit industrial Ethernet gateways can handle up to 16 concurrent connections (from SCADA/HMI/ PLC) without compromising response time or transmission reliability. • Data Prioritisation Most switches already offer packet prioritisation between administrative-level (SCADA/HMI) and controllevel (PLC) devices. Some Ethernet gateways are now also capable of providing device-level (fieldbus I/O) data prioritisation to enhance Quality of Service (QoS) and improve determinism. The core of industrial automation consists of SCADA, PLC, and I/O devices. Switches and gateways enable fieldbus-toEthernet convergence by providing network communication between these core devices at field, control, and supervisory-level networks. For performance optimisation of large-scale industrial automation networks, it is imperative that each


Configuration & Monitoring Efficiency of switch and gateway configuration during fieldbusto-Ethernet integration has previously been reliant upon the expertise of system integrators. Gateway configuration can be e x t re m e l y t i m e - c o n s u m i n g , which requires manual input and is verified through system trial-and-error. In addition, the isochronous nature of hard real-time industrial automation systems does not tolerate delays and requires precise calibration of critical parameters, such as gateway response timeout settings, to prevent system errors. Furthermore, optimising PLC network management requires tools for network configuration and monitoring, not only to ensure reliable operation and immediate event notification, but also to provide effortless maintenance updates to minimise system downtime. Manual input of I/O modules and device timeout settings can take many hours, if not days, to complete. Intelligent switches and gateways can assist system integrators and control engineers to deploy, configure, and update industrial automation segments within the network to quickly e n a b l e p ro d u c t i o n o n t h e factory floor. Flexibility To Converge Applications Industrial automation network infrastructures can span across multiple plants in multiple remote locations, where various applications are performed in various industrial environments. Switch and gateway flexibility allows operators to optimise PLC network deployments with devices that are best-suited for applications in industries such as chemical plants, waste water

treatment, and oil refineries. Industrial automation networks will require different types of gateways and switches for different applications. These applications can require different port densities and various combinations of port types, such as fibre, PoE, SFP ports with Fast Ethernet, Gigabit, or 10GbE connectivity. F u r t h e r m o re , i n d u s t r i a l automation applications, whether indoors or outdoors, can present some of the most challenging conditions, pushing devices to their limits. Environmental factors such a s e x t re m e t e m p e r a t u re s , vibration/shock, corrosion, dust, moisture/humidity, surge, and Electromagnetic Interference (EMI), will require the deployment of industrial-grade devices with industry-specific certifications and compliance. Many vendors offer a selection of switches and gateways specifically designed for a targeted application, without much consideration on how these devices can impact the automation network as a whole. Consequently, operators can be left with a multi-vendor network which does not work as a cohesive whole and can severely impact overall network performance and manageability. Converging various systems and applications within the PLC network requires a wide spectrum of switches and gateways. These switches and gateways should not only be designed and calibrated specifically for each application, but they should also help to bring about PLC network optimisation as a whole. Deploying a smart and reliable industrial control system requires an optimised industrial network design to help ensure a high-performance, efficient, and flexible platform for daily operation.

ENQUIRY NO. 592

network component operates with cohesive and timely efficiency.

ENQUIRY NO. 4804 June/July 2013 | industrial automation asia  57


eBOOK EXCLUSIVE

There are many threats to a server room’s physical environment. Remote monitoring plays an important part in limiting the impact of service interruptions. By Andrew Leong

Organisational Imperative

M

any companies have to rely on robust computer networks to maintain communications links, operations, and in general conduct everyday activities. Network security is of the utmost importance to any organisation, and is a major focus for any IT department. Typical organisations have their own secure data rooms where they store and analysis information relative to their organisation. However, within the server rooms a lot can go wrong. To name a few, fires can break out, servers can crash, air conditioning systems can fail, and so on. Incidents, such as these, can radically affect productivity, and the overall functioning of an organisation, and ultimately this will impact the company’s bottom line and its ability to function effectively. If these scenarios play out, the unplanned downtime can cost an organisation not just its reputation, but also many thousands, or even millions of dollars in lost revenue depending on the industry, industrial automation asia | Feb/Mar 2013

the size of the company, and the level of disruption. Many IT managers are very familiar such dangers exist, however many of these managers overlook ways to monitor their computer’s physical environment.

The Threats Protection, such as, spyware protection, antivirus software and firewalls are well known and used extensively in various industries. It is important however that these programs are updated regularly as new threats are always evolving and changing. In the case of a computer room’s physical environment, where environmental conditions can reduce a networks’ performance or cause damage to the room’s equipment. As the performance of these rooms have a direct effect on an organisation’s effectiveness, a company will need safeguards in place. Employing a remote monitoring system in this regards is therefore a good investment and

Andrew Brigmond, Kissimmee, Florida, US

Monitoring:


Balázs Kovács, Budapest, Buda, Hungary

is essential for any organisation. Such equipment would give IT professionals the ability to track environmental conditions and respond to small changes before they have the opportunity to alter network activity. One environmental condition that is of concern is heat build up, as the many computers in these room’s give off large amounts of heat due to their heavy usage. This alone can cause computers and equipment to stop functioning. This effect will only get worse as computing equipment gets more powerful and more ‘heavy lifting’ is required from this equipment. The size of these rooms and the amount of active equipment also have an impact on their temperature. On average, a PC uses about 300 to 400 watts of electricity, which ultimately turns into heat that needs to be managed as to not cause damage to the equipment. If the heat is not managed then internal components can be damaged or a fire could break out, not just damaging one machine, but many and perhaps the whole room.

Monitoring is essential to ensure the smooth operation of computing equipment within server rooms responsible for an organisation’s data.

This is why advanced monitoring equipment is required and why it is worth the investment by organisations. One common solution to cooling these rooms down, is the use of an air conditioning system. By using a thermostat in conjunction with such a system the temperature of these server rooms can be managed and controlled. Many companies now have a dedicated air conditioning unit used with the addition of backup power and protection. This is so the server room can operate independently from the rest of the organisation. If power fails within an organisation the server room can still maintain the correct temperature and continue normal operation independent of the state within the organisation at large.

Advanced Monitoring If remote monitoring equipment is installed within these computer rooms then such systems can quickly detect small changes in the environment and alert staff to the existence and often their severity. IT managers or individuals can then act to asses the situation and act in the appropriate manner. Other more advanced remote monitoring systems have more programmability. Software programs can be configured to change its state when pre-programmed thresholds are crossed. This is particularly useful in locations that are remote and where manning such stations is not always viable. For a server room to be monitored there needs to be sensors in place, and these sensors need to be placed correctly to be effective. As an example, if a sensor is placed within an individual rack system then the temperature of that rack system is monitored accurately, but the temperature of the room at large is not. Therefore, IT managers need to make sure additional sensors are placed throughout the room to gain an accurate picture of the room’s state. Other than heat, another issue is water damage. Water sensors can be placed within the room, but again the correct placement needs to be achieved. If the sensors are not placed correctly then the room will not be monitored correctly resulting in potential serious consequences. When sensors are placed within these room, they are typically programmed to issue an alert that is well below the required threshold. One problem that can occur in such circumstances is response time from IT managers. IT managers are well aware of this and they should therefore be encouraged to respond to alerts once they occur rather than allow complacency to set in. Feb/Mar 2013 | industrial automation asia


EVENT REVIEW

Hannover Messe Hannover Messe is over for another year with the 2013 edition held between April 8 to 12. What was apparent from the get-go was an emphasis on what is known in Germany as Industry 4.0, which is an initiative being push by the German government. “The world’s most important industry trade show has proven itself as a driver of the fourth industrial revolution,” commented Dr Jochen Köckler, member of the Deutsche Messe Executive Board. This edition of the show was a successful year by all accounts with one in every four visitors coming from abroad. Most came from the EU as well as from Southern, Eastern and Central Asia. The Netherlands and China were the most strongly represented countries, followed by India, Italy, Austria and Denmark. Also, this year saw a new visitor service centre that hosted 17 international business delegations with 800 participants. The show hosts a matchmaking service which saw participating customers more than double compared with the previous year, with around 4,000 participating in 2013. Special technology tours were arranged including Automation, Energy, GreenTech, Process Efficiency, Metropolitan Solutions, and 58  industrial automation asia | June/July 2013

2013

Industry in Motion that proved to be popular with special tours arranged for delegations, totaling 1,200 participants in all.

The Exhibitors In terms of exhibitors, there were 6,550 representing 62 countries, of which over half came from abroad. Dr Köckler remarked: “The outstanding registration numbers and the strong participation by international exhibitors are indicative of the great need for worldwide discussion of the future of industrial manufacturing.

Par ticularly in the context of current global economic challenges, Hannover Messe is of great importance for exhibiting companies.” The partner countr y this year was Russia, which had a representation of 177 exhibitors. After Germany, the largest number of exhibitors came from China, Italy, Turkey, Russia and France.

Industry 4.0 Industr y 4.0 is par t of the German governments high technology strategy, and it is


technology advance, after the steam engine, mass production and automation, as the ‘fourth industrial revolution’.

Partner Country

primarily concerned with smart factories and moving IT back into the factory environment. “Machines, facilities, work pieces and components will trade data and information in real time in the future,” explains Dr Köckler. “This will give an extra push towards more efficiency, security and resource protection in manufacturing and logistics.” Exper ts describe this new

Russia has partnered with the fair this year for the first time. “The country is increasingly important when it comes to energy. A lot of the automation exhibitors are here due the fact Russia is planning to modernise its whole industry,” commented Onuora Ogbukagu, spokesperson, Hannover Messe. In terms of promotion, the country occupied 5,000 sq m of space, with 180 exhibitors, and was primarily located in the energy sector, the automation sector, but also the research and development sector of the fair. In terms of other countries represented at the fair Mr Ogbukagu remarked: “For the

first time this year, more than half of the exhibitors come from other countries. The leading country is China, followed by Italy, and then there is Turkey, Russia, and France.”

The Future In terms of the future Mr Ogbukagu remarked that one of the main objectives for 2014 and beyond is to raise the internationality of the visitor side: “Right now, we look at 2011, with our 230,000 visitors, around 25 percent of them came from abroad. There are plans in the next couple of years to double our international visitors, and that is the main objective.” April 8 - 12, 2013 Hannover Messe Hannover, Germany ENQUIRY NO. 4901

Exhibitors’ Thoughts

Hans-Gerd Hilger

Hans-Gerd Hilger, marketing manager solutions industry business, Schneider Electric: “Asia is a very important market for Schneider, the company makes more than 30 percent of its total turnover in China, and has been in the country for over 20 years. We have a higher turnover in China compared to that of Europe.”

Kai Ristau

Kai Ristau, head of international sales & business development, Beckhoff Automation: “Industry 4.0 has been initiated by the German government. It is mixing automation with the IT world. It is talking about smart industries and the ‘internet of things’. It is talking about bringing the industry, the factories in relation to the IT world.”

Klaus Stark

Klaus Stark, GM international operations, Pilz: ”The drivers for the safety market in Asia are coming up so our business is growing. That is why we set up an Indian office in 2012 and in 2013 we started expanding into Taiwan. It is a real growing market.”

Martin Rostan

Martin Rostan, executive director, EtherCAT Technology Group: “We regard Hannover Messe as a very important part of our communications strategy with both our members and the general public. The fair is, as we see it, the only remaining truly international trade show in Europe.”

June/July 2013 | industrial automation asia  59


EVENT REVIEW

Global Strategy IAA spoke with Dr Jürgen Geißinger, vice chairman, president and CEO of Schaeffler on Hannover Messe and the company’s overall operations. Schaeffler, who participated in this year’s edition of Hannover Messe, seen an increase in sales during the last calendar year in heavy industries, aerospace, and customer products. In Asia/Pacific, the organisation currently holds a market share of 23.1 percent, nearly doubling from its 2007 market share of 13.5 percent.

IAA: What are your impressions of Hannover Messe this year? Jürgen Geißinger (JG): We have good traffic on the booth, and on the first day it was good compared to the previous year. It is a good environment, and a good sign at the moment. The economy in Europe is down, but we are expecting this to pick up in the second half of 2013. We are seeing good signs at this year’s fair. IAA: What is the most important success marker for the company? JG: Honestly, a little bit of everything. Innovations are very important for us and if you look around our booth you will see many of the company’s own innovations. Also, globalisation, building new factories, and local R&D are very important. For example, in our R&D centre in China we have about 700 engineers, and it is growing very fast. We are also investing in local R&D in India, South Korea, Japan, and South America, as it is very important for us. As such, it is manufacturing, it is R&D, including customer support. This is what gives us the boost that drives our success. IAA: What risks does your company face and what is your strategy to counter those risk over the next five years? JG: The risk is always the economy. I think we are in a very good position with regard to our products. We have a lot of future oriented products. We

Dr Jürgen Geißinger, vice chairman, president and CEO of Schaeffler

are involved in automotive, in renewable energy, in mobility, and with assembly and tool machines. We are in a good position. Also, we have our global manufacturing network, with all our factories we have built up. The only question is what happens to the economy. Such as, concerns over whether the economy will be stable, will China grow as it has been, and what will happen in India over the next couple of years as it has been a very successful market. At this point America is picking up, and also Europe. Once Europe is stabilised then we are quite positive for the future. IAA: How do you promote your company’s culture given your global presence? JG: In terms of employees we are doing a lot. We have international management training, where we bring all our middle management and other management together. This is so that they get the chance to know each other, and they are on the same page in terms of the company’s strategy. In the company we exchange people, it is not just from Europe to Asia, but also from India to China, and North America to India. As such, we exchange our people and therefore their cultures to the company’s global sites, which promotes a common understanding. IAA: How do you connect with your customers? JG: It is important that we listen to the customers and that is why we need our local engineers. It is important to have the right t e c h n o l o g y, t h i s d o e s n o t mean high technology or low technology, it means having the right technology for the market.

ENQUIRY NO. 4902

60  industrial automation asia | June/July 2013


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Applications are now open - Reserve your booth today!

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Co-located with

Ms. Jennifer Chiah Tel: +65 6500 6738 Fax: +65 6296 2771 j.chiah@koelnmesse.com.sg

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ENERGY EFFICIENCY ASIA

25 - 27 September 2013, Centara Grand & Bangkok Convention Centre at CentralWorld Organized by Koelnmesse, and co-located with Clean Energy Expo Asia, Energy Efficiency Asia is a 3-day Conference and Trade Fair focusing on improving energy efficiency in the buildings, utilities and industry sectors. Energy Efficiency Asia brings together industry energy professionals, energy efficiency experts and key stakeholders to meet, share experiences and discuss solutions towards implementing a successful energy efficiency program.

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Supported by the Departments under the Ministry of Energy, Thailand

Ms. Khoo Su Ling Tel: +65 6500 6718 Fax: +65 6294 8403 sl.khoo@koelnmesse.com.sg

Ms. Jennifer Chiah Tel: +65 6500 6738 Fax: +65 6296 2771 j.chiah@koelnmesse.com.sg

ENQUIRY NO. 589

Co-located with


EVENT REVIEW

Schaeffler has been expanding, increasing its market share in Asia, as well as opening and expanding plants in 2012. One of the most recent plants includes one in Russia, in the Volga region. This will be the company’s first manufacturing facility in the country. The company sees five key trends, of which it has developed new offerings around, ie: efficiency, mobility, energy, urbanisation, and integrated industries. It also has a global technology network, training its staff locally, and exchanging knowledge across its network. IAA: How does Schaeffler train its global network of engineers? Helmut Treffer (HT): One of the first things you need to do when you build up R&D facilities in a foreign country like China or India, is find the right people. You will need to find people with experience, either with a bearing background, or people with an application background, such as, a machinery or transmission manufacturer. We h a v e a s t r u c t u r e d training program with different competence levels. I believe what is important is not only the technical knowledge, but also the philosophy of how to handle a project or an enquiry. What is important is knowing how to apply the know how when you work on a project with a customer. Our aim is to have the same philosophy across all our global R&D centres. The desired result being that if China and Brazil are given the same enquiry or technical challenge they should come up with the same solution independently of each other. IAA: Could you say more about Schaeffler’s engineering training? HT: As I said, we have different levels of training. We start with 62  industrial automation asia | June/July 2013

Global Training For Local Needs IAA spoke with Helmut Treffer, VP Sector Managements Industrial OEM, Schaeffler, on the company’s training programs and its global presence.

Helmut Treffer, VP Sector Managements Industrial OEM, Schaeffler

the basic training, and then they gain experience for two to three years. We have also sent many Asian engineers to Germany or to other countries for one or two years. Only then, if you work together with the other colleagues you can learn this philosophy and then you can work on the actual projects. Also, our training is based on real projects, not theoretical training. We have sent many specialists from the headquarters, in Germany, to China, and also to India, and South Korea, for two to three years to build up their experience.

The next important point is we have established a global technology network. This is sector specific because we always come from a specific application standpoint. For example, at the steel plant, we have specialists for steel applications in the headquarters, and also in China and in India, and also other countries. These people work together and exchange information. If there is one technical problem in China, the Chinese engineer can tap into this network of competence. A colleague in Brazil may have a similar challenge, and the two


ENQUIRY NO. 581


EVENT REVIEW

and having a good management structure. Offering them good career opportunities within the company is important also. It is of course a big challenge, I agree, and we have taken a lot of effort to minimise the impact from this. Also, I believe working in a global environment is attractive for young engineers. IAA: What are the challenges in entering new markets, especially in Southeast Asia (SEA)? HT : I know SEA quite well, because I was responsible for setting up our infrastructure there five years ago. The first challenge is of course, finding the right people who have the skills and will be loyal to the company. Another challenge is the industry structure in Southeast Asia. In many areas, it is Japanese dominated. This makes a market more difficult for us to access, as compared to being dominated by a Western company. Integrated Industries: One of the company’s five key trends.

colleagues can share what they have learned. This has worked successfully for us. Knowledge and, as such, solutions, can be transmitted and shared throughout our global network. IAA: Is it a concern that if you train the local engineers too well they will end up leaving the company and using their skills elsewhere? HT: Of course, this has been a challenge, not only in China, but also in India and Southeast Asia. In China I believe we have been very successful, as our turnover rate is low, especially in R&D. I think it is about selecting the right people, treating them well, 64  industrial automation asia | June/July 2013

IAA: Are there any markets that you are very good at in SEA, which you are not elsewhere? HT: Yes, there are some specific markets. For example, Palm oil, because this industry does not exist much outside SEA. The countries with a large Palm oil industry are Malaysia and Indonesia. This industry uses specific equipment that we have developed special products for. As such, this is a good example of developing products based on understanding local needs. IAA: What is the strategy for choosing the right OEMs, and how do you find a good OEM? HT: It is very important that we share the same philosophy. If the customer is willing to work with us on the development, then this is what we are looking for. Of

course, it should be a company with high standards in quality. IAA: Different geography and regions have different kinds of demands. The European side tends more towards technology, Asia tends more towards cost-ef fectiveness. How do you strategise based on these differences? HT: On average, Europe and America are geared towards higher performance, but also in Asia, there are some areas where there is a clear trend towards higher performance. I also think if Asian manufacturers want to export to the Western world, they have to meet this higher performance. This is actually one area where we work very often with Chinese or Indian manufacturers to upgrade their product or to make sure that their product is good enough for expor t to Europe. I think it is a mixed world. I mean in India and China, we have areas where the demand is pretty high. If you look at sectors like railway or wind, where either the risks are very high or the safety is very important. Another area is heavy industries like steel or mining. For example, let us take a steel plant or a paper machine and if your bearing fails, and the whole machine stands still, the loss of production, per hour, can be as much as E1,000 (US$1,308). In those cases it is ver y crucial to make sure that those bearings work, and they are of the highest quality. It does not make a big difference whether the bearings are more than or less than E10,000, because one hour of downtime comes at a much higher cost.

ENQUIRY NO. 4903


ENQUIRY NO. 577


products & Services ABB: DCS Controller

B&R: Industrial Processor

Forming the core of the Freelance Version 2013, Distributed Control System (DCS) from ABB is the AC 900F controller. This controller includes a Secure Digital (SD) card that allows users to load and backup a configuration, without needing an additional computer. Four built-in Ethernet ports and two serial ports that support both Modbus and IEC 60870-5-104 telecontrol protocols on Ethernet are included. The controller has transmission speeds of 100MB/sec, and includes support for Profibus master modules to allow line redundancy and high availability, with no single point of failure. A single controller supports up to 1,500 I/O, and up to 10 direct I/O modules.

The Automation PC 910 from B&R was developed in close cooperation with the US semiconductor manufacturer Intel. Core i3, i5, and i7 processor chips are being used in this Automation PC series. Integrated graphics were placed directly on the processor chip, which increases graphics performance and allows the DirectX 11 API programming interface to be used to display complex 2D and 3D graphics. It also provides support for audio output, pointing and input devices as well as network communication. USB 3.0 interfaces, two gigabit Ethernet ports, a serial interface and additional modular interfaces for communication networks such as RS-485 and CAN round off the options available on the Automation PC 910.

Enquiry no. 4904

Baumer: LBFS/LFFS Switch

Baumer’s CleverLevel series LBFS/LFFS switch is used in conjunction with the optional configuration software ‘FlexProgrammer’. Frequency deviation technology extends the device’s application areas beyond simple filling level monitoring. It is designed to detect different media (eg: foam and liquid) as well as contaminants (eg: oil on water) in the same tank. In addition, the level switch prevents pumps from running dry even in viscous or sticky media. Using the configuration software, the switching range can be adjusted as required to ignore foams during maximum or minimum monitoring. It is also possible to simultaneously monitor the devices internal signal, while the thresholds are adjusted by a mouse click within the graphic representation. Enquiry no. 4905 66  industrial automation asia | June/July 2013

Enquiry no. 4906

Emerson: Digital Valve

Controller

Emerson’s Fisher Fieldvue DVC6205 remote-mount digital valve controller is suited for applications in which accessibility, temperatures (up to 120 deg C), vibration or confined space make integral mounting difficult or impractical. Industries such as pulp and paper and nuclear power have typically prefered to isolate valve mounted instruments from harsh environments. With this device, only the valve position feedback is mounted on the control valve, while the remainder of the digital valve controller can be mounted over 300 feet (91.44 m) away in a less severe or more accessible environment. Enquiry no. 4907


products & Services

Fuji Electric: Uninterruptible

ifm electronic: Flexible

The 7200BX series uninterruptible power system (UPS) from Fuji Electric comes equipped with the company’s own power semiconductor technology (IGBT) for sales to the Asian markets. The demand for UPS has increased in recent years in Asia as a source of backup power for power outages on production lines and for IT equipment. The company developed the 7200BX series to meet needs specific to Asian markets. Its features included easy to expand, an increase in overall efficiency, and a reliable system architecture. Applications include mission critical systems in internet data centres, offices, telecommunications and service sectors, with release in China, South Korea, and Southeast Asia.

ifm electronic has developed an RFID system for harsh environments like identifying tools, monitoring production steps, quality assurance, automotive and conveying industries. This robust, IP67 evaluation unit is equipped with an integrated Profibus DP interface and a web server. Parameters are set via a laptop. The RFID evaluation unit features four antenna terminals, or digital I/Os. The antenna concept guarantees easy connection of the LF, HF antennas by means of M12 connectors. The RFID system platform is used in production for ease of use and flexible parameter setting, allowing users to solve identification tasks.

Power System

Enquiry no. 4908

RFID System

Enquiry no. 4910

Hypertherm: Quick

Invensys Operations Management: PLC

Quick disconnect torches from Hypertherm’s Centricut brand are available for Kaliburn Spirit and ProLine series plasma systems, providing owners of those products with an affordable alternative. The Centricut torches leverage the company’s two-piece torch technology. This technology is said to make it easier and faster to switch torches and change out consumables. Its engineers have also optimised gas and coolant flow for better performance and reliability. In addition, they are manufactured with a coupler ring that improves an operator’s grip on the torch, allowing for tighter connection between the torch head and the base. Finally, the torches feature a dust seal to keep metal chips and other debris from collecting on the coupler threads.

The Triconex General Purpose system from Invensys Operations Management is a SIL2certified high availability, fail-safe and fault-tolerant controller that helps protect the lifeline of the business. Redundancy, diagnostics, error checking and failure modes are all built into the system as standard. This version also features OPC Universal Architecture communications connectivity, which maximises interoperability between systems and streamlines connectivity through open platform architecture and future-proof design. The communications interface module contains an embedded OPC UA server to provide a cohesive, secure and reliable crossplatform framework for real-time data, alarms and events. It also implements X.509 certificates for additional, enhanced security protection.

Disconnect Torch

Enquiry no. 4909

Enquiry no. 4911 June/July 2013 | industrial automation asia  67


products & Services

Kepware: Server Platform

Nord: Worm Gear Unit

Kepware Technologies, a software development company focused on communications for automation, has enhanced to its KEPServerEX platform, offering solutions to simplify communications management. These enhancements are designed to Improve connectivity for power distribution, extend OPC support, and simplify EFM configuration. The KEPServerEX 5.11 enhancements include support for Windows 8 and Windows Server 2012, in addition to the IEC 61850 MMS Client Driver, the OPC XML-DA Client Driver, and the EFM Simulator. This platform is designed to be flexible and scalable, and connects, manages, monitors, and controls diverse automation devices and software applications.

The SMI series from Nord Drivesystems offers a range of worm gear units in a robust, one-piece unicase housing in five sizes with a maximum torque of 427 Nm. Larger output bearings allow users to choose increased shaft diameters than the previously available series. In addition, the large bearings ensure a much extended service life. The aluminium permanent mould casting process was optimised for this series, resulting in a smooth surface that prevents dirt build-up. Closed worm gear versions of this series are washdown-capable, and can therefore be easily cleaned along with other systems during plant cleaning processes.

Enquiry no. 4912

Enquiry no. 4914

LCM Systems: Large Digit

Prosoft Technology: Gateway

LCM Systems has a range of Large Digit Display indicators for use in crane, lifting and hoisting applications. There are three models within the LD Range: the LD-Process is suitable for process analogue current and voltage signals; the LD-Strain is for use with strain gauge based sensors and the LD-Serial, is used as a slave display with connection by RS232 or RS485 interfaces. There are a number of options available that can be mixed and matched, depending on a client’s particular application. All three indicators come in either four or six digit versions with digit heights ranging from 57-400 mm that can be viewed from 25-200 m, respectively.

The AN-X2-AB-DHRIO gateway from Prosoft Technology offers a range of solutions including migrating Remote I/O Drives and PanelViews to newer PowerFlex Drives and PanelView Plus 6 terminals on EtherNet/IP. The gateway allows upgrading of these legacy components without modification of PLC code. The gateway can also be used to migrate Remote I/O networks to ControlLogix or CompactLogix PACs. When upgrading legacy control systems the gateway allows users to monitor the changing states of I/O in the existing application. This in turn allows them to build and verify the control system before switching over, minimising downtime.

Display Indicators

Enquiry no. 4913 68  industrial automation asia | June/July 2013

Enquiry no. 4915


products & Services

Schneider Electric: Box Cameras And Micro Domes

Box Cameras

Micro Domes

The Pelco Sarix IL10 Series mini box and micro dome cameras from Schneider Electric, the first of more than 50 Sarix fixed IP camera products are released in 2013. Delivering on customer needs and preference, the high definition IP network cameras offer a solution for video security needs in small- and mediumsized businesses. This series of cameras produce high-quality, colour HDTV video, and the integrated fixed focal length lens enables sharp scene alignment and easy installation. The series, which comes in four models, is suitable for a variety of indoor environments. Enquiry no. 4916

Turck: IP20 Ethernet Switch Turck extends its in-cabinet Ethernet switches with a multimode fibre optic port unit for reliable, fast performance in process and factory automation environments requiring conversion from fibre to copper media. The complete product line, consisting of unmanaged and managed models, has also been approved for use in hazardous locations per UL and Atex ratings. These IP20-rated Ethernet switches conform to all necessary IEEE standards and support a wide range of Ethernet protocols including EtherNet/IP, Modbus TCP and Profinet. To accommodate diverse requirements, in-cabinet Ethernet switches are available in small expansion 5- to 8-port unmanaged configurations and 8-port managed options. All models contain RJ45 sockets for fieldbus connection and removable terminals for power. Enquiry no. 4917

Westlock: Smart Positioner The ICoT 5400, from Westlock, is a smart positioner that has passed the ITK 6.0.1. criteria. The positioner is a fully digital positioner that provides reliable measurement of valve stem position for a wide range of actuators, including spring and double-acting variants. Designed to meet Foundation Fieldbus protocols, the positioner fulfills the control requirements of the petrochemical, oil and gas industries and can be incorporated into customers’ plant network infrastructures. Based on the existing ICoT 5000 series of digital positioners, the enhanced 5400 features improvements to both firmware and hardware, including a graphical display, an extended trunk length, single loop integrity and multi-drop capabilities for up to 32 devices per segment. Enquiry no. 4918

Yokogawa Electric: CCD

Colour Camera

Yokogawa Electric has released the Fieldeye II series of allweather CCD cameras for the monitoring of plant facilities and premises. This model, the FC33U, is non-explosion proof and has pan-tilt zoom functionality. The company plans to release an explosion proof model by the end of 2013. This series is compact in size and is expected to provide a boost to the company’s plant monitoring solution business. Applications include the monitoring of processes and facilities at oil, petrochemical, chemical, pulp and paper, pharmaceutical, food, and iron and steel plants. Enquiry no. 4919 June/July 2013 | industrial automation asia  69


An International Exhibition of Oil & Gas Companies, Technologies & Supporting Industries

Incorporating: Offshore Vietnam 2013 An International Exhibition of Offshore Technologies

Endorsed and Supported by :

Brought To You By :

Singapore Industrial Automation Association

Fireworks Vietnam Part Of The Fireworks Trade Media Group

ENQUIRY NO. 597

Vietnam’s Largest Oil & Gas Technology Showcase At The Heart Of The Industry!


Calendar Of Events 2013 Jul 2 – 5 MTA Vietnam 2013 Saigon Exhibition and Convention Center (SECC) Ho Chi Minh City, Vietnam Singapore Exhibition Services Pte Ltd Email: mta@sesallworld.com Web: http://www.mtavietnam.com

3 – 5 Indo Renergy Expo & Forum Jakarta Convention Centre Jakarta, Indonesia PT Napindo Media Ashatama Email: info@indorenergy.com Web: http://www.indorenergy.com/

4 Vision Developers’ Forum NTU@one-north (Buona Vista) Singapore Basler Email: seminar@baslerweb.com Web: www.baslerweb.com/SG_IAA

5 Vision Developers’ Forum Hotel Equatorial Penang Penang, Malaysia Basler Email: seminar@baslerweb.com Web: www.baslerweb.com/SG_IAA

28 – 30 Electronics Assembly and Packaging Technology Expo 2013 Shenzhen International Convention & Exhibition Center Shenzhen, China Reed Exhibitions Email: vera.ng@reedexpo.com.hk Web: http://www.atexpochina.com/en/

28 – 31 Taipei International Industrial Automation Exhibition 2013 Taipei World Trade Centre Nangang Exhibition Hall Taipei, Taiwan Chan Chao International Co Ltd Email: automation@chanchao.com.tw Web: http://www.autotaiwan.com.tw/en/

sep 4 – 6 Semicon Taiwan 2013 TWTC Nangang Exhibition Hall Taiwan Semiconductor Equipment and Materials International (SEMI) Email: staiwan1@semi.org Web: http://www.semicontaiwan.org/en/

17 – 19 Oil & Gas Thailand BITEC Bangkok, Thailand Fireworks Media (Thailand) Email: thai@asiafireworks.com Web: http://www.oilgasthai.com/

25 – 27 Clean Energy Expo Asia 2013 Centara Grand & Bangkok Convention Centre Bangkok, Thailand Koelnmesse Email: j.liong@koelnmesse.com.sg Web: http://www.cleanenergyexpoasia.com/

oct

28 – 30 Thailand Lab 2013 BITEC Bangkok, Thailand VNU Exhibitions Asia Pacific Email: thailandlab@vnuexhibitionsap.com Web: http://www.thailandlab.com/

Kuala Lumpur Convention Centre (KLCC) Kuala Lumpur, Malaysia Expomal International Sdn Bhd Email: igem@expomal.com Web: www.igem.com.my/2013

28 – 1 Nov Singapore International Energy Week Marina Bay Sands Singapore Energy Market Authority Email: ema_siew@ema.gov.sg Web: www.siew.sg

nov 5 – 9 China International Industry Fair 2013 Shanghai New International Expo Centre Shanghai, China Shanghai World Expo (Group) Co Ltd Email: ciif@shanghaiexpogroup.com Web: www.ciif-expo.com

5 – 9 Industrial Automation Show 2013 Shanghai New International Expo Centre Shanghai, China Hannover Milano Fairs Shanghai Ltd Email: ias@hmf-china.com Web: www.industrial-automation-show.com

13 – 15 Oil & Gas Indonesia 2013 Jakarta International Expo Jakarta, Indonesia PT Pamerindo Indonesia Web: http://www.pamerindo.com/events/6

dec 4 – 6 Oil & Gas Vietnam 2013

2 – 4 Power Gen Asia 2013

aug

10 – 13 IGEM 2013

IMPACT Exhibition & Convention Centre Bangkok, Thailand PennWell Conferences & Exhibitions Email: exhibitpga@pennwell.com Web: www.powergenasia.com

Indoor Sports Complex Vung Tau City, Vietnam Fireworks Vietnam Email: viet@asiafireworks.com Email: http://www.oilgasvietnam.com/

9 – 10 MITF 2013 Putra World Trade Center Kuala Lumpur, Malaysia Expo Works Email: info@expoworks.com.my Web: http://www.manufacturing-expo.com.my

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


i n d e x ADVERTISER

PAGE NO

ABB PTE LTD

IFC

576

31

593

advantech co singapore pte ltd

ENQ NO

BASLER ASIA PTE LTD

9

585

CONTRINEX (SEA) PTE LTD

29

580

expoworks sdn bhd

63

581

EXXON MOBIL ASIA PACIFIC

3

578

faulhaber singapore pte ltd

45

595

FIREWORKS MEDIA THAILAND CO LTD

53

586

fireworks vietnam

70

597

FLUKE SOUTH EAST ASIA PTE LTD

37

596

FUJI ELECTRIC ASIA PACIFIC PTE LTD

7

588

honeywell pte ltd

11

459

ICP DAS CO, LTD

57

592

IFM ELECTRONICS PTE LTD

41/47

583/584

IGUS SINGAPORE PTE LTD

33/43

590/591

JEC COMPOSITES

49

582

koelnmesse pte ltd

61

589

OBC

415

Mitsubishi Electric Asia PTE Ltd NATIONAL INSTRUMENTS

5

587

PT. PAMERINDO INDONESIA (OIL & GAS)

65

577

WEIDMULLER PTE LTD

55

594

YASKAWA ELECTRIC (SINGAPORE) PTE LTD

1

579

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energy guide Supplement

A PREMIUM PRODUCT OF INDUSTRIAL AUTOMATION ASIA

Take aim and hit your target market in energy: Tailored for energy producers, distributors, and consumers. The Energy Guide

Photos courtesy of: ABB, Rockwell Automation, Siemens, AspenTech

EDITORIAL FOCUS Power Generation Here we bring the different sources of energy together and discuss the technology and process of power generation.

Renewable Energy

Renewable Energy is exploding throughout Asia with solar energy and wind energy being the most desirable depending on location. Smart grids are also taking off, inducing new ways to orchestrate energy management across conventional sources and renewable sources.

Energy Efficiency

Energy policy plays an influential role in improving energy efficiency with the region’s energy authorities in introducing mandatory energy management requirements to reduce energy use and greenhouse gas emissions.

Oil & Gas

The Oil & Gas sector is growing in Southeast Asia, especially the LNG market with strong demand seen across the region. This section can discuss such trends and the technologies required to get the most out of this industry.

Email : salesiaa@epl.com.sg Tel: (65) 6379 2888 Fax: (65) 6379 2805

www.iaasiaonline.com

The age of energy renewal is upon us, as the number of companies embracing the technology of energy efficiency is increasing and more organisations are aligning themselves with government policy to reduce CO2 emissions. Improving efficiency, taking advantage of renewable sources of energy, and improving on your green credentials is no longer an option, it’s essential. This guide is aimed towards energy producers, distributors, and consumers, as we understand the essential need to benefit the broad energy market through these three categories. connect with us


ENQUIRY NO. 415


IAA June July 2013