Page 1

June/July 2008

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


Engineering Through

Integrated Design

Proximity +Presence Sensing Warming To EDDL

hermal Imaging

Dynamic Heat Analysis

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contents june/July 2008





Lean Paradigm: The Skinny Lean implementation can be accomplished through increased automation as well as through the use of manufacturing hardware and software. By Augustine Quek


Proximity & Presence Sensing: The Fundamentals

Lean Paradigm: The Skinny

MES Software: Lean On MES

MES software has been embraced as part of Lean, yielding the benefits of continuous improvement, reduced waste, improved response times as well as optimised energy usage in support of addressing sustainability initiatives. By Gordon Benzie, Apriso Corp


Industrial Ethernet Network: Best Laid Plans


CONTROL POINT Batch Control: Recipe For Flexibility


Temperature Transmitters: Warming Up To EDDL

Enhancements to the EDDL IEC 61804-3 standards have improved advanced setup and diagnosis of high-end temperature transmitters. By Jonas Berge, senior PlantWeb consultant, Emerson Process Management


Implementing a flexible solution to handle a large permutation of recipes and mixes, simplifying production while maintaining consistent quality. By Anna Russo, marketing coordinator and channel support EMEA, Wonderware

Thermal Imaging: Polaroid Prediction

Taking our visual sight capabilities beyond the visible spectrum to the radiated heat spectrum can alert us to processes that warrant further attention. By Bill Dove, HVAC systems trainer, Fluke

Implementing an industrial Ethernet network that is cost effective, durable and reliable. By Daniel Santos, field application engineer, N-Tron Corp




Proximity & Presence Sensing: The Fundamentals An introduction to proximity sensors and understanding the right selection for the right application. By Wong Ruting, engineer, Omron Asia Pacific


Proximity & Presence Sensing: Looking Further

With advancements in technology, expectations and demands of proximity sensors have and will continue to rise. The industry requires faster switching and more reliable sensors. By Alan Lok, product marketing engineer, ifm electronic


2  industrial automation asia | June/July 2008

Thermal Imaging:

Polaroid Prediction


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contents june/July 2008


Green Packaging: The Money Tree

Industrial Automation Asia (IAA) is published 8 issues per year by Eastern Trade Media Pte Ltd 1100 Lower Delta Road #04-02 EPL Building Singapore 169206. Tel: (65) 6379 2888 • Fax: (65) 6379 2805 Website: Email: Subscription Rates: IAA is available to readers on subscription in Singapore at S$60.00 per annum. Subscription by airmail to readers in Malaysia is also at S$60.00 per annum; and Asia Pacific, America, Europe and other regions at S$100. Refer to the subscription card in each issue for further details. For more subscription information Fax: (65) 6379 2806 • Email: 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.




Appetite For Expansion


Green Packaging: The Money Tree

Appetite For Expansion

Expanding an F&B plant by increasing capacity, improving delivery punctuality and speed, and doubling picking and dispatch performance. By Han Kian Kwang, regional director, business development, Dematic

Balancing economic and environmental objectives in CPG (consumer package goods) and F&B packaging. By Chin Ying Loong, VP, ASEAN/Australia/New Zealand and Daniel J Staresinic, global marketing director, consumer products, Siemens PLM



Collaborative Engineering Through Integrated Design Collaborative engineering as an area of strategic and functional innovation in the engineering world aims to provide concepts, technologies and solutions for product development. By Denis Branthonne, regional director, ASEAN, Autodesk Asia



4  industrial automation asia | June/July 2008

Hannover Messe 2008

The world’s leading industrial trade fair, Hannover Messe, took place with key themes of energy, automation, future technology and young engineering talent.


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.

Refer to pg

for Advertisers’ Enquiry Numbers

Regulars 8 News 16 Profibus Association S E Asia 18 CAN in Automation 20 Fieldbus Foundation 22 EtherCAT Technology Group 56 Products & Services 67 Calendar of Events 68 Advertising Index / Ad Sales Office 68A Product Enquiry Card Cover: Fluke South East Asia Pte Ltd




Lean Back And

EnjoyThe Rewards

“To add speed, add lightness,” alleged British car manufacturer Lotus’ founder, Colin Chapman. Although the late Mr Chapman was referring to cars and not manufacturing, this well-known quote makes sense in the business world as well, albeit in the guise of ‘Lean’. Coincidentally, it is another car maker that is credited for bringing this concept to the factory floor. Japanese automotive company Toyota developed the idea of Lean with the Toyota Production System. The principle behind this is the elimination of waste, streamlining, if you will. The continued evolution of Lean has resulted in the inception of tools that assist in its implementation. One example, further explored in a feature article in this magazine, is the leveraging of manufacturing execution system (MES) software to achieve Lean. It goes on to extol the virtues of integrating software into a Lean programme, and rightly so. Lean has also been associated with ‘green’ in recent times, and not just for phonetic reasons. In fact, the connection between lean and green is gaining increasing recognition throughout the world. Events like the Lean And Green Summit, which takes place in mid July this year, encourages the application of Lean, geared in particular towards environmental operations. Embracing the concept of Lean is only the first step. The execution is the next. The disposal of ‘waste’ for one must be carried out with a discernible eye. Effective Lean implementation does not include mindless cost cutting. Lean can be practiced in a multitude of ways. A simple procedure such as systematic arrangement of workplace tools can be Lean enablers. Any operation, irregardless of size, can be ‘lean-ed’. Although it is not a mathematical impossibility, the basic implication of Lean is the addition to productivity by the subtraction of effort. This surely presents an attractive proposition.

The continued evolution of Lean has resulted in the inception of tools that assist in its implementation

Published by:


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

Kenneth Tan

Managing Editor

Eileen Chan assistant editor

Derek Rodriguez Editorial Assistant

Serene Ho Senior Art Director/Studio Manager

Lawrence Lee Graphic Designer

Katherine Ching Sales & marketing Manager

Caroline Yee

Circulation MANAGER

Caroline Rayney Circulation Executive

Agnis Lim Contributors

Gordon Benzie, Augustine Quek, Denis Branthonne, Dietmar Brüss, Han Kian Kwang, Jonas Berge, Bill Dove, Alan Lok, Daniel Santos, Wong Ruting, Chin Ying Loong, Daniel J Staresinic, Anna Russo Editorial Consultants

Jim Pinto

Industry Analyst

Alastair Ross Director, Codexx Associates Ltd

supported by:

EASTERN HOLDINGS LTD executive Board Chairman


Kenneth Tan

Financial Controller

Robbin Lim



Trade Media Pte Ltd an Eastern Holdings Ltd company

Head Office & Mailing Address: Eastern Trade Media Pte Ltd 1100 Lower Delta Road #04-02 EPL Building Singapore 169206 Tel: (65) 6379 2888 • Fax: (65) 6379 2805 Website: Email: MICA (P) No. 327/10/2007 ISSN 0219/5615 PPS 1561/7/2008 (000553) Co Reg No. 199908196C

Derek Rodriguez Assistant Editor

6  industrial automation asia | June/July 2008

Colour Separation: Pica Digital Pte Ltd Printer: Fabulous Printers Pte Ltd


Industry News New Intrinsic Safety Concept Singapore: German automation company Pepperl + Fuchs organised a technology seminar on May 15 in Orchard Hotel, Singapore, taking the opportunity to introduce their latest technology to the Asian region. Thomas Klatt, business development manager, fieldbus systems, flew down from Mannheim, Germany to present the company’s DART and WirelessHART technologies to the invited guests, which included both vendors and journalists. First launched at Interkama 2008 during the recent Hannover Fair, the patented DART technology was one of the nominees for the prestigious Hermes Award. DART, which is an acronym for Dynamic Arc Recognition and Termination, describes a new approach to bring high-powered intrinsic safety to the field. The technology allows the use of field devices with a power rating of up to 50 watts. This presents a key benefit over current technology which limits energy by limiting the power.

Mr Klatt describes the advantages of WirelessHart.

characteristic which DART is able to detect and switches off the circuit in case of any spark formation, before the current is able to reach a level to build up sufficient heat for ignition. It is available in two versions. DART high-power allows the use of devices

of electric power per segment even inside explosion hazardous areas. Factors, such as cable length and device characteristics can greatly influence the response time for spark detection. DART deals with such negative influences by connecting the device via a decoupling

A simple DART circuit consisting of a power supply, cable and load.

DART is able to detect failures of the electric system right from the beginning and quickly shuts off the power supply before any critical situation can arise. The basis for such early detection is the fact that any spark leads to a sudden peak of the current and voltage within the respective electric circuit. This peak shows a very specific 8  industrial automation asia | June/July 2008

with a power consumption of up to 50 watts inside the Ex area. Typical examples are industrial PCs including control terminals and displays, LED lighting systems, sensors with high power rating, instruments for analysis and solenoid valves. Via a fieldbus infrastructure, DART is able to provide up to eight watts

module to the energy supply. This module ensures a clearly defined electrical response pattern, always providing the system with a signal that allows the dependable detection of critical situations requiring immediate shutdown of the circuit. ENQUIRY NO. 4101

Industry News

ABB Nominated For Award Singapore: ABB celebrated its nomination for the KNX award in early June at an event held at the Singapore Flyer. Two building projects in Singapore, supported by the company, were selected out of more than 5000 entries worldwide for the award in Frankfurt Germany, an global award that recognises the most innovative and technically advanced home and building control systems. The National Library Board was nominated for the special award. Xilinx Asia Pacific headquarters, located within Changi Business Park, was nominee for the energy efficiency award. Both buildings adopted the ABB i-bus KNX intelligent installation system, for twilight zoning control, motion sensors and switches. This system is user-friendly, multi-functional, and designed for predictive maintenance. 集博.pdf 2008/5/20 PM “With ABB’s4:47:41 experience in NLB building and Xilinx, our upcoming

projects to support building management systems will ensure more buildings in Singapore go greener and be energy efficient,” said Lim Say Leong, assistant VP for marketing, automation products division. ABB has the highest number of installed control systems for buildings and homes in Singapore, ranging from apartments and bungalows, educational and Mr Foo giving the opening address. public institutions like schools and hospitals, to commercial industries while lowering environmental impact. and hotels. Some of their ongoing and The ABB i-bus is one of the many ways upcoming projects will continue to ABB’s technology can help save energy, apply their energy efficient technologies cut emissions, and reduce costs. More to hangers, universities, bungalows in than ever before, ABB’s power and prime areas, resort island homes, and a automation portfolios are delivering hospital and sports complex. energy efficient products, systems and President and country manager, solutions to enhance the value of our James Foo said, “We enable our stakeholders.” ENQUIRY NO. 4102 customers to improve performance










June/July 2008 | industrial automation asia  9

Industry News

Yokogawa Wins DCS Awards Singapore: Five Yokogawa group of to technology companies in Asia Pacific have won six innovation and Frost And Sullivan market leadership our unparalleled awards for distributed control systems customer care. (DCS) under the industrial process Yo k o g a w a ’s control category for Singapore, leadership Indonesia, Malaysia, Australia and New position is the Zealand, and market leadership award result of our for DCS and automation and software commitment in Thailand. to customers Frost And Sullivan, a growth through reliable consulting company, recognised p r o d u c t s , Yokogawa as the market leader for committed and its Centum DCS in six countries in experienced Asia Pacific because of its market people, and life share, extensive market adoption, cycle support growth trends as well as excellence in services.” technology innovation. According to Satish Lele, director, The award ceremony was held on industrial practice at Frost And Sullivan: 25th April 2008 at the Mandarin Oriental “This year Frost And Sullivan launched Hotel, Kuala Lumpur, Malaysia. country specific analysis of the markets In his award acceptance speech, in Southeast Asia, which allowed us to Kersi Aspar, executive VP of Yokogawa understand the dynamics and future Engineering Asia, expressed trends of the region and its implication delightfully: “The market leadership for automation companies. As 2007 was award firmly endorses our commitment for business, many SG-723-Dry mini 85x114 30.04.2008another 16:32strong Uhr year Seite 1

automation players have responded with significant investment in the region. Through these awards we recognise some of these best companies who have demonstrated excellence in products, service and technology to emerge as market leaders.” ENQUIRY NO. 4103

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Non-Drip Quick Connect Couplings

CEJN’s new product range of modular non drip couplings is adaptable to most fluid application and system requirements. This couplings are compatible with working pressure up to 20 Bar (290 PSI) and temperatures up to 315°C (600°F), making it suitable for a variety of low-pressure fluid applications in which lines needed to be connected and disconnected easily, safely and without leakage. Sizes available include body sizes from 1/4 inch to 1 inch.

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Industry News

Macawber Beekay Chooses GE Fanuc


Advantech Solution Day Singapore: The Advantech Solution Day is an interactive seminar for those interested in industrial development and technical trend to share and contribute his business know-how. This event, which will be held on the 15th of July in Singapore at the Raffles City Convention Centre, will provide a platform for exchanging information about the rapidly changing machine markets and technology trends, as well as face to face meetings for discussions and networking. The company will showcase their new product technology and future product development concepts as well.

INTELLIGENT FLUID SENSORS • Maximum operating comfort The new generation provides a recessed button for storing modified values in addition to two buttons for quick menu scrolling. • Highest level of flexibility with mounting A freely rotatable sensor body with a tilted display which can be rotated using software by 180° and which offers all installation possibilities. • Highest level of precision 0.5 % of the full scale with pressure sensors and 0.2 K with temperature sensors provides a very large range of applications with very few variants. • Highest level of system reliability The robust design featuring a stainless steel housing, EMC and IP67 degree of protection provide the highest levels of operational safety.

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New Delhi, India: GE Fanuc Intelligent Platforms, a unit of GE Enterprise Solutions has received a order from Macawber Beekay of New Delhi, India for a hardware and software material handling solution that provides environmental pollution control and energy conservation. The US$1 million order includes a complete hardware and software solution delivering centralised digitised data and multi-platform control resulting in a cost-effective control solution. “Macawber Beekay has been working closely with GE Fanuc for five years,” said Vish Palekar, GM, GE Fanuc, India. “All of our work together has paid off with this substantial solution purchase.” The two companies have worked together on various projects with NTPC, BHEL, Indian state electricity boards and private power companies including Reliance, Jindals and Vedanta. The company was eager to get these projects in production because India’s Energy sector is booming with a proposed addition of 78,000 MW in the next five years. This represents almost 60 percent of the current installed capacity in the country. The demand has been created due to huge infrastructure development in the past few years with most of the capacity being added in coal-based thermal power plants. Many of the local power plant equipment manufacturers are contributing to this growth.

June/July 2008 | industrial automation asia  11 S0200_80x240_Druck-Temperatur_EN.indd 1

01.02.2008 08:03:54

Industry News

Industrial Controller Receives Certification

Metso Expanding In China

Taipei, Taiwan: Tibbo’s DS1000 BASICprogrammable industrial controller is now IP68-compliant. IP (‘International Protection Rating’) is a widely used standard of ruggedness. The higher the IP number is, the more resilient is the rated device. The DS1000 becomes dust- and waterproof once a special secondary waterproof cover is installed. The cover attaches to the top and accommodates up to six signal cables that can securely ‘exit’ through it.

Shanghai, China: Metso will expand its production capacity and office facilities in Shanghai, China, through an investment of €20 million (US$31 million). The investment supports Metso’s global presence strategy by increasing production resources in Asia’s growing markets. Metso will establish new facilities for their valve factory and supply centre, for automation system production, and for sales, a project unit and engineering in China. About half of the investment will be allocated to a new office and factory building. The rest will be spent on acquiring machinery and equipment and on building the factory infrastructure. The building plans will be completed late this year and the actual construction will begin next year. Operations in the new facilities will commence in early 2010. After completion of the facilities, all Metso Automation units in Shanghai will move into the same facilities. The number of employees in the units is estimated to grow by 400 and will rise to about 650 employees in 2011. Production capacity will be quadrupled from 2007 to 2011. Today, Metso operates in 16 different localities in China, where it has about 2,700 employees. Measured in net sales, China was Metso’s third largest country. The 2007 net sales of its subsidiaries operating in China totaled €197 million (US$306 million) and sales to China totaled €543 million (US$843.6 million). The total value of Metso’s investments in China in 2006-2008 is about €100 million (US$155.4 million). ENQUIRY NO. 4107


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12  industrial automation asia | June/July 2008

5/28/08 7:23:19 AM

Industry News

New Robot For Package Goods Market California, USA: Adept Technology Inc announced its inverted SCARA robot for the packaged goods market. The Adept Cobra s800 inverted IP65 brings high speed handling solutions to case and carton loading applications. “This new inverted Cobra robot is

ideal for customers needing extremely fast packaging needs and who face floor space challenges,” said John D u l c h i n o s , p re s i d e n t o f A d e p t Technology. “The inverted model not only saves valuable floor space but it is the fastest robot in its class and is impervious to dust, dirt and liquid

making it a perfect fit in multiple packaging applications.” The robot is a SCARA robot system for mechanical assembly, material handling, packaging, machine tending, screwdriving, and many other operations. ENQUIRY NO. 4108

SunPine AB Chooses Invensys


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Texas, USA: Swedish bio-refinery SunPine AB will use the Invensys SimSci-Esscor's PRO/II simulation software for modeling a new biodiesel refining operation in Piteå, Sweden. The new plant, which is a member of the Solander Science park biofuels collaboration, converts crude bio oil byproducts of pine pulping into second-generation biodiesel for shipment to diesel refining facilities. "Efficient operation of the distillation column is critical to profitability of biodiesel production, impacting cost, output and regulatory compliance. The more accurately we can simulate our operation, the more effectively we can optimise availability and utilization of the distillation column. We are confident that the PRO/II simulation software has all of the functionality that we need for this important objective," said Magnus Wikman, acting MD for SunPine. SunPine will be using a newly patented process to manufacture biodiesel from a main feedstock of crude tall oil (CTO), a byproduct of pine pulping, and combine it with vegetable oils such as Jatropha or Castor oils to create crude tall diesel (CTD). With environmental approvals recently in place, SunPine AB will begin initial construction in the summer of 2008, with biodiesel production start planned for October 2009.

June/July 2008 | industrial automation asia  13


Industry News

Piab And Austar Form Partnership Shanghai, China: Piab Shanghai, a subsidiary of the Swedish based industrial vacuum technology company, has entered into a strategic partnership with Austar, a Hong Kong based company dedicated to providing products and services to the pharmaceutical industry with focus on high-end customers. Founded in 1991, Austar has branch offices and subsidiary companies in Beijing, Shanghai, Shijiazhuang, Guangzhou, and Chengdu, servicing over 300 customers in the pharmaceutical industry and scientific research institutions with high quality equipment from over 30 manufacturers from Western countries. With PIAB’s range of vacuum conveyors in 316L stainless steel, and Austar’s capability in providing engineering, installation, and commissioning services, customers can derive synergistic benefits from a total solution provider, whether it is in the dosing equipment, feeding the tablet presses, or any other production processes where handling of powder is required.



14  industrial automation asia | June/July 2008

Beijer Electronics Receives Award Sweden: The ‘European Human Machine Interface Competitive Strategy Leadership of the Year’ award, for significant gains in market share via excellent market strategy, was presented by global growth company Frost And Sullivan, whose significant experience in recognising innovative strategies prompted praise for Beijer Electronics’ HMI division. “Key mergers and acquisitions and alliances have yielded significant benefits to the company such as increased penetration into new markets and gains in market share,” said Frost And Sullivan research associate Shibaprya Saha. “These include the acquisition of ElektronikSysteme Lauer which enabled strategic penetration into the German market, the opening of a subsidiary in China to facilitate expansion into the Asian market as well as a landmark deal with Mitsubishi Electric and the acquisition of Taiwanbased Hitech Electronics.” ENQUIRY NO. 4111

Industry News

Honeywell To Acquire Metrologic Instruments

Tridium Wins Award

New Jersey, USA: Honeywell has announced a definitive agreement to acquire Metrologic Instruments Inc, a manufacturer of data capture and collection hardware and software, for approximately US$720 million. The agreement is subject to customary closing conditions, including regulatory review. Metrologic will be integrated Roger Fradin with Honeywell Security, part of Honeywell’s Automation and Control Solutions (ACS) business. Metrologic’s revenue was approximately US$246 million in 2007. “The acquisition of Metrologic adds to the momentum we have generated throughout our ACS business, by focusing on high-growth industries, and is consistent with our disciplined approach to acquisitions,” said Roger Fradin, president and CEO of Honeywell ACS.

California, USA: Based on its recent analysis of the remote monitoring services market, Frost And Sullivan recognises Tridium Inc with their 2008 North American Global Excellence of the Year award for its successful implementation of its global growth strategy. “Tridium has demonstrated global growth excellence by implementing unique strategies to achieve increased revenues, expanded client base, and improved capabilities and services,” says Frost And Sullivan research analyst Jorge Moreno. “The fact that today there are over 100,000 instances of the company’s Niagara Framework worldwide operating in over 9,000 installations in 43 countries is testimony of its welldeveloped global expansion strategies.” To fulfill on these strategies, Tridium employs direct and indirect sales channels. The direct channel consists of a sales force that sells the technology to original equipment manufacturers or to large end users such as multiple commercial property developers, universities, telecommunications companies, hospitals, retail establishments and hotels. The indirect channel is served by very qualified system integrators with designated geographic regions.



COMMUNICATION CAN BE THAT SIMPLE We talk Ethernet – even into the Ex Zone.

After all, it has always been the better choice to work with the right type of experts. Pepperl+Fuchs Pte Ltd · 18 Ayer Rajah Crescent · Singapore 139942 Phone: +65 6779-9091 · Fax: +65 6873-1637 eMail: ·


Relying on generally accepted standards throughout the plant is always better than using proprietary solutions. That is why Pepperl+Fuchs insists on TCP/IP communication via Ethernet. One of the latest examples of this philosophy is VisuNet Remote Monitor – the PC control unit that can be located within the Ex Zone. It not only offers a modular design, which allows individual configuration to match any specific needs, it also extends the Ethernet into the category II 2G, II 2D, Class I Division 2 sections on the factory floor. This puts an end to costly proprietary solutions and opens the way to a new age of transparent communication without limits.

June/July 2008 | industrial automation asia  15

Industry Updates Continued Growth Of Number Of Profibus And PROFIBUS DP nodes Profinet Nodes Predicted ith more than a million Profinet nodes already Number of installed, Profinet is established in the field of Nodes 2007 industrial automation. Each node represents an automation end device with a Profinet interface. Devices such as switches, hubs and routers, ie structural components of the Ethernet infrastructure, are not counted. To get an over view of the definite number of nodes already on the market, PI (Profibus and Profinet International) tasked a notary with the job of determining the number of installed nodes. The initial count covered the time period from 2002 to 2007 and yielded this: By the end of 2007, 1.14 million Profinet nodes had already been installed in various applications. Joerg Freitag, deputy chairman, is setting ambitious goals. He commented: “We estimate that three million Profinet nodes will have been installed by the end of 2010. This corresponds to an average annual increase of 37 percent.” This puts the market forecast above average. A study published by the ARC Advisory Group in January 2008 sees a 27.5 percent annual increase on the global market for Ethernet-capable devices over the next five years. The

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16  industrial automation asia | June/July 2008

Profibus Nodes 25 m 23.3 m

In 2007: 4.5 m nodes!

20 m

18.8 m

At the beginning of 2004, we said:

15 m

Over the next 4 years, we will double the number of installed Profibus nodes to 20 million.

10 m











PI (PROFIBUS & PROFINET International) PI Press Conference April 2008 “With Profibus, we have the largest installed base on the fieldbus market,” said Mr Freitag. “By integrating today’s fieldbus systems into Profinet via a proxy, we offer optimal protection of investment for device manufacturers and system operators.” The Profibus market looks just as good. Last year, PI recorded the highest growth ever of installed nodes. In 2007, the number of nodes purchased grew to a new all time high of 4.5 million. This means that 23.3 million Profibus nodes had been installed by the end of 2007. The number of Profibus PA devices increased by 120,000 to 750,000 in 2007. The total number of such nodes installed in the process industry amounts now to 4 million, which corresponds to an additional 700,000 nodes in 2007. The number of established Profisafe nodes and systems experienced especially vigorous growth. The number of such nodes increased by 180,000 to 410,000 in 2007, and the number of Profisafe systems by 15,000 to 41,000.

Visit Profibus At These Events June 10 – 13, ICA 2008 Kuala Lumpur Convention Centre Kuala Lumpur, Malaysia Hall 1 Stand No 109 – 112 June 24 – 26, Water Expo 2008 Suntec Convention Centre Singapore Level 4 Stand No M13 ENQUIRY NO. 4114

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Utilising CANopen safety and controller technology for mobile machines in bridge inspection equipment. By Dietmar BrĂźss, ifm electronic

At A Dizzy Height


he implementation of CANopen Safety (CiA 304) as an extension of the communication profile has made it possible now to exchange data safely on the same bus cable in parallel to the PDO communication between the CAN network participants. The prerequisite of this communication possibility is that the bus participants generating or reading these safety-relevant data support the corresponding CAN mechanisms and have hardware according to the requested safety category. As for the design of a safety controller and the implemented application software the correctness of the data has to be ensured on a safe bus system. If an error occurs during communication, there has to be a reaction within a sufficiently short period of time and the machine has to be passed into a safe state. 18  industrial automation asia | June/July 2008

At the same time it also has to be ensured that the implemented safety functions do not affect the communication of the normal (not safety related) bus participants. Safety In Bridge Inspection Since this application could not be implemented in one individual safe controller module, only complex additional wiring to other external safety components could have solved this requirement without the use of CANopen Safety. The bridge inspection equipment can be used on the road and/or on rail depending on the design. Due to the design of the vehicles, obstacles such as railings, noise barriers or crash barriers can be overcome. In its working position underneath or alongside the bridge the unit can be moved sensitively. Basket-type units

can also be used as mobile elevating work platforms. Irrespectively of its type, the safety of the workers and the operators has to be ensured at all times. The control modules process all sensor and actuator signals and the control signals from the remote control. T h e e l e c t ro n i c a n d e l e c t ro mechanical end switches connected prevent, for example, the vehicle passing into an unstable position during set-up and work. Before there is a risk of tilting, the relevant hydraulic pumps are switched off. The platform or the basket can then only be moved into a safe, stable position. Simultaneously all signals are monitored for correctness and plausibility thanks to the extended diagnostic functions. A short circuit or a break in the wire of an actuator cable is, for example detected, evaluated and immediately transferred to the safe operating system. Depending on the configuration of the inputs or outputs there is an automatic reaction to the error. Permanent checking of the processor, the memory and the other hardware by the operating system enables constant monitoring of the control process. Safety and high uptime are guaranteed by this system structure. The data of the individual control modules are constantly exchanged between the individual controllers and the remote radio control via the CAN bus. The correct transfer of the safetyrelevant data of the safety controllers is ensured by the implemented CANopen safety protocol.

identifiers. Message 1 contains the original user data, message 2 the same data which are, however, inverted bit by bit. The data are read and compared via the operating system. Non-safe network participants can also receive and evaluate the data from the safety controllers. Besides the corruption of data during transfer the cyclic update (SCT) of the SRDOs the correct time interval (SRVT) between the redundant message 2 and the original message is also monitored. In order to verify the correct function of the periodic transfer of the SRDO, data refresh is monitored via the SCT mechanism (SCT: safeguard cycle time). Only if the data are repeated within the set time are they valid. Otherwise the receiving controller will signal an error and will pass into the safe state, ie the safety-relevant outputs are switched off.

A second mechanism (SRVT: safety-relevant object validation time) ensures that the time between the two SRDO messages is kept. Only if the redundant message 2 was transferred within the set time is the message valid. In case of an error, the controller will also pass into the safe state and switches the safety-relevant outputs off. The identifier range reserved for CANopen is integrated in the predefined connection set of CANopen. Due to the identifier structure of CANopen the number of SRDOs, which can be sent in a network of safety-related participants (producers) is limited to 64 (usually 32 receiving and 32 transmitting identifiers). The number of participants receiving these data (consumers) is only limited by the network structure and the general CANopen mechanisms. ENQUIRY NO. 4115


Safety Protocol The CANopen safety data are read and evaluated via the two integrated CAN interfaces of the safety controllers via two different CANopen stacks. Since they are freely programmable devices and due to the internal design of the implemented different CANopen interfaces, no object directory (OD) was implemented for the exchange of the safety parameters. All settings, network commands and the data transfer are processed via the library functions ‘Can Safety Transmit’ and ‘Can Safety Receive’. Programming of the application is effected directly via CoDeSys with the standardised IEC 61131-3 languages and enables the user to create a clear and easy application software. The safe data are transferred between the network participants via SRDOs (SRDO: safety-relevant data object). An SRDO always consists of two CAN messages with different

June/July 2008 | industrial automation asia  19

he Fieldbus Foundation participated in the Interkama international process automation trade exhibition and conference in Hannover, Germany, in late April of this year. Following a theme of ‘Tea & Technology’, the Fieldbus Foundation German marketing committee invited visitors to sample a choice of 30 different specialty teas while discussing displays demonstrating Foundation technology from 24 of the world’s leading automation equipment suppliers. Marc Van Pelt, VP, EMEA operations, said: “Foundation technology has enjoyed another year of unparalleled

industry growth and now accounts for over two thirds of process fieldbus revenues. As the global technology-ofchoice for process automation in both brownfield and greenfield projects across the world, we believe that Foundation has become the standard, providing a total control system infrastructure that enables significant plant performance and economic improvements.” At the exhibition, Mr Van Pelt presented an update on several aspects of Foundation fieldbus, including a summary of the market, illustrations of the deliverable benefits of the technology, an update of the Fieldbus Foundation safety instrumented

functions (SIF) development project and upcoming demonstration at Shell Global Solutions, Amsterdam, The Netherlands, and progress made by the field device integration (FDI) project team and the newly established wireless cooperation team. He also highlighted some of the Fieldbus Foundation’s EMEA marketing  activities and end user initiatives scheduled for 2008. Following Interkama 2008, the F i e l d b u s F o u n d a t i o n ’s G e r m a n marketing committee has decided to participate in Interkama 2009, as well as Achema 2009 in Frankfurt, Germany. ENQUIRY NO. 4116

‘Tea & Technology’ At Interkama

20  industrial automation asia | June/July 2008

Addition To Board Of Directors

End User Seminar: Singapore he Fieldbus Foundation organised an end user seminar in Singapore on May 16 of this year. Stretching over one day, this event titled ‘Fieldbus Life Cycle Made Easy - Designing, Operating, Maintaining Foundation FieldBus for Any Plant’ attracted over 100 participants. The speakers included Lin Yew Chai, Honeywell, who introduced fieldbus basics, Tiago Carneiro Da Costa, Smar, whose presentation was on ‘Configuration and Interoperability’, and Jonas Berge, Emerson, who talked about ‘Using A Handheld Field Communicator’. Further end user seminars have been planned around the globe, with the next one scheduled at June 10 in Mexico City, Mexico. The next Asian stop will be in Qindao, China on June 19. ENQUIRY NO. 4117

he Fieldbus Foundation has named Timothy H (Timm) Madden, senior instrumentation and controls consultant for ExxonMobil Development Company, to its board of directors. In addition to chairman J o h n B e rr a o f E m e r s o n Process Management, Fieldbus Foundation board members now include: Kenneth Deken, Rockwell Automation; David Eisner, Honeywell; Motofumi Matsumura, Fuji; Satoru Kurosu, Yokogawa; Jim Porter, DuPont; Dr Gunther Kegel, Pepperl+Fuchs; Timm Madden, ExxonMobil; Mark Taft, ABB; Hirozume Sone, Yamatake Corporation; John Eva, Invensys; Hans-Georg Kumpfmueller, Siemens AG; and Fred Cohn, Schneider Electric. ENQUIRY NO. 4118

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Industry has more than 20 years’ experience of SATEL radio modems. They can be used to set up flexible management, monitoring and control systems, such as robotruck guidance, electronic stock management and access control. A dedicated operatorindependent network means lower costs and facilitates use over short and long distances. Radio modems are suitable especially for places where mobile machinery or a wide operating area make cabling difficult.

The 9140 family from Fluke’s Hart Scientific division lightens your field calibration workload at every turn. Their compact size and weight make them the most portable field calibrators in their class. Fast heating and cooling plus automated and documented calibrations save time. Plus the built-in reference thermometer, two measurement channels, and 24 V loop power supply ensure top accuracy. ALARM

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June/July 2008 | industrial automation asia  21

Asia EtherCAT Robots

Win RoboCup Competition

he soccer robots of the Dutch Team Tech United Eindhoven won the RoboCup German Open in Hannover. The Tech United Robots use EtherCAT for interfacing to drives, sensors and actuators. Each of the tree wheel robots weighs around 35 kg and acts autonomously without remote control. Communication with the other team members is established through wireless Ethernet. Vision is provided by a camera pointing upwards towards a parabolic mirror, thus creating a 360° view of its surroundings. Using this image, the robot is able to determine its position. The robot controller is a mini-pc with an EtherCAT Open Source master. RoboCup is an international joint project to promote artificial intelligence (AI), mobile robotics, and related fields. It is an attempt to foster AI and robotics research by providing a standard problem where wide range of technologies can be integrated and examined. RoboCup chose to use the soccer game as a central topic of research, aiming at innovations to be applied for socially significant problems and industries. The ultimate goal of the RoboCup project is to develop a team of fully autonomous humanoid robots by 2050 that can win against the human world champion team in soccer. ■ ENQUIRY NO. 4119

ETG Members Number Over 750 he growth rate of the EtherCAT Technology Group is further accelerating. In the last 12 months, membership of the worldwide group increased by 250 – an average of one new member every business day. There are now 760 companies from 41 countries listed on the membership roster. The member distribution shows the migration from a primarily German to a truly global association. At the end of 2003, 70 percent of the 35 founding members were from Germany. Today the percentage of German members is down to 38 percent. The US has the second highest percentage of members, followed by Japan, Switzerland, Italy and South Korea. In Asia, the ETG now has 130 members, and most of its regional offices, in Tokyo, Beijing and Seoul. The group is managed from Nuremberg, Germany, and since 2007 there has been a regional office in Austin, Texas, USA. In addition to the fast growing membership figure, the number of EtherCAT implementations is quickly increasing. Today over 550 implementation kits have been sold altogether. Over 150 master stacks have been sold in addition to the free of charge downloads from open source master websites. 22  industrial automation asia | June/July April 2008 2008


760 696

700 634


575 515


458 404

400 357 321




169 117





89 33




Nov 03 May 04

Nov 04

May 05

Nov 05

May 06

Nov 06

May 07

Nov 07

May 08

Thirty-three vendors have already introduced servo drives with an EtherCAT interface, and more are under development. In this respect, it has already caught up with the market leading fieldbus systems of the previous generation. ■ ENQUIRY NO. 4120


ifm electronic

issues & insights

Lean Paradigm:

The Skinny Lean implementation can be accomplished through increased automation as well as through the use of manufacturing hardware and software. By Augustine Quek


ean manufacturing or lean production, is a systematic approach to identifying and eliminating waste through continuous improvement by flowing the product at the demand of the customer, as opposed to batch and queue. It is the synergistic and mutually supporting techniques and activities for running a manufacturing or service operation, sometimes simply know as ‘Lean’. The principles and practices of Lean have now grown beyond being practiced in a manufacturing plant, to influencing a myriad of industries and organisations, from accounting to construction to zoo exhibit designs. This diversity of applications is what is known as the Lean Paradigm. Modern Lean Lean implementation is focused on 24  industrial automation asia | June/July 2008

getting the right things, to the right place, at the right time, in the right quantity to achieve perfect work flow while minimising waste and being flexible and able to change. These concepts of flexibility and change can principally be accomplished through increased automation, and tools like Lifecycle Management, through manufacturing hardware and software. Many types of software on the market currently help industries in a Lean environment. For example, Boothroyd Dewhurst’s design For manufacture and assembly (DFMA) software allows the analysis of cost effects of design decisions at any time during the product development cycle. The software can help estimate the difficulty of assembly, eliminate unnecessary parts and assembly

tooling, and DFMA concurrent costing design products that are less costly to manufacture, making products Lean from the start. Advances in machinery automation also promote Lean production and streamline manufacturing processes. Robotic automation options, for example, often combine robots with conveyance systems for flexibility in part handling. B o s c h R e x ro t h ’s C a r t e s i a n modular automation systems at Sitech Sitztechnik GmbH (Polkowice, Poland, and Wolfsburg, Germany), a subsidiary of Volkswagen Group, in particular the Rexroth TS 2plus transfer system at Sitech’s Polkowice manufacturing plant, is a typical example. The system has enabled the automotive seat manufacturer to design a high-volume, automated

assembly line that saves factory floor space, lowers cycle times, and improves quality. This provides not only the short cycle times required, but also the ruggedness needed for the production of steel structures for car seats. The twin-tier system setup conducts the workpiece pallets back underneath the flat top chain on a double belt, saving around 30 percent of the space originally planned. With loads of up to 100 kg and workpiece pallets measuring 160 x 160 mm to 1040 x 800 mm, the TS 2plus system covers the entire spectrum of automation, producing roughly 53,000 seats and 77,000 seat backrests per week. An Enabler A complementary tool, Lean Lifecycle Management (LLM) is another method to enable Lean manufacturing deployment in dynamic, complex supply chains. For example, the

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i2 Lean Lifecycle Management is a comprehensive planning, scheduling and execution solution specifically designed to enable Lean manufacturing in dynamic, complex supply chains dealing with multiple fulfillment modes and diversified product portfolios. The solution tightly integrates planning and execution by automating these functions as repeatable and standardised processes. The i2 LLM key capabilities include level production considering critical factory floor constraints and pacemaker heijunka scheduling and execution. The basic features include visual interactive execution dashboards for problem detection and resolution, quick ‘what-if’ scenario management, kanban management and execution for value stream synchronisation, and visible Lean metrics for structured continuous improvements (kaizen). Although Lean concepts originated on the shopfloor, analogues occur in other businesses such as construction,

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Lean Construction A major influence of Lean has been in the construction industry. Lean construction is a translation and adaption of Lean manufacturing principles and practices to the end-toend design and construction process. The Lean construction movement goes back to at least 1993, when the International Group for Lean Construction (IGLC) was founded. Unlike manufacturing, construction is a project based-production process. Lean construction is a way to design production systems to minimise waste of materials, time, and effort in order to generate the maximum possible amount of value. Designing a production system to achieve the stated ends is only possible through the collaboration of all project participants, such as the owner, A/E, constructors, facility

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June/July 2008 | industrial automation asia  25

issues & insights managers and end-users, at early stages of the project. This goes beyond the contractual arrangement of design/build or constructability reviews where constructors, and sometime facility managers, merely react to designs instead of informing and influencing the design. Veridian Homes, headquartered in Madison, Wisconsin, uses what it calls kaizen redline events to review all of its home plans. In these kaizen events, every part of the design would be examined for ways to simplify, reduce duplicate efforts and standardise work. R e p re s e n t a t i v e s f ro m e a c h department, including key subcontractors, would first review a specific plan. Then, the team presents its findings and concerns regarding that plan to all design, construction, management and customer-service people in a monthly meeting. Key issues are discussed and opportunities for improvement (OFI) are identified. Other data regarding customer complaints and defects are also brought to the meeting for analysis. Many times an issue that surfaced in one plan is identified as common to all plans, which can then be resolved by OFI teams. This helped

Veridian develop plans that are more constructible, and has led to major improvements. These includes reducing drafting time per model by more than one hour, reducing model homes sold cycle from 32 to 15 days, reducing inspection (and inspection costs) by 50 percent while reducing defects by more than 50 percent, among other things. Lean construction supplements traditional construction management approaches with two critical and necessary dimensions for successful capital project delivery; by requiring the deliberate consideration of material and information flow and value generation in a production system and different project and production management (planningexecution-control) paradigms. Lean Accounting Another area that Lean has impacted is in accounting. Lean manufacturing and traditional accounting conflict in several ways. These conflicts often produce considerable difficulties. Traditional accounting was designed to support mass production. In addition, traditional cost accounting reports were developed to present an accurate view of the company to outsiders, not to help managers run their operations better.

Advances in machinery automation also promote Lean production and streamline manufacturing processes. 26  industrial automation asia | June/July 2008

Traditional cost accounting reports were not developed to help managers run their operations better.

For example, some non-financial measures including lead times, scrap rates and on-time deliveries show significant improvements; yet reducing inventory reduces assets and increases expenses on traditional financial statements. As a result, a growing number of companies are implementing Lean accounting concepts to better capture the performance of their operations. Lean accounting moves from traditional cost accounting to a system that measures and motivates good business practices. Instead of categorising costs by department, costs are mapped to value streams. A value stream includes everything done to create value for a customer that can reasonably be associated with a product or product line. Lantech Inc, a packaging solutions provider, has experienced the benefits of Lean accounting. Previously, Lantech would only look at the cost for each piece or work order and then add an overhead allocation. By reporting value stream as costs are tracked at the product line level, revenues, materials, supplies, and scrap for each line becomes clearer. With this information, managers could see whether material use, scrap rates and labour costs for a product line were moving up or down. Valuing inventory is also faster because inventories tend to be much lower than in traditional manufacturing operations, focusing on producing only to meet customer demand. This has enabled Lantech to complete its year end inventory count in just several hours.

Lean Mindset ‘The Lean Benchmark Report: Closing the Reality Gap’ by the Aberdeen Group, released in March 2006, it found that ‘There is a large performance gap between companies simply using Lean techniques on the shop floor versus those that have built a culture based on Lean thinking.’ Although Lean aims to make the work simple enough to understand, to do and to manage, it should also instill a culture of flexibility and ability to change. More importantly, all of these

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concepts have to be understood, appreciated, and embraced by the actual employees who build the products and therefore own the processes that deliver the value. The cultural and managerial aspects of Lean are just as important as, and possibly more important than, the actual tools or methodologies of production itself. Lean has come a long way since the early 20th centur y, and has effectively penetrated nearly every single form of human endeavour. Leaders today in a wide range of industries, non-profit organisations, government agencies, and other areas are finding ways to apply the principles of Lean as a means of producing goods and delivering services that creates value for the customer with the minimum amount of waste and the maximum degree of quality. ENQUIRY NO. 4201

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and less time than the traditional system of mass production. The Woodland Park Zoo in Seattle is one example of a handful of nonprofits that has been trained in Lean process techniques. Boeing volunteers, using Lean techniques, helped designed its new US$6.5 million penguin habitat, reducing its exhibit design cycle to eight months from 18.

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Lean Enterprises A natural transition therefore, occurred from Lean concepts being used in businesses to Lean enterprises. A Lean enterprise is a system for organising and managing product development, operations, suppliers, and customer relations. The Lean practice of improving workflow is just as applicable to administrative paperwork flowing through an office as it is to parts flowing on the factory floor. The concept of detecting defects immediately when they occur is applicable to administrative work, or to engineering design. Similarly, there can be equal concern about optimising the flow of information and the flow of materials. Business and other organisations now use Lean principles, practices, and tools to create precise customer value, goods and services with higher quality and fewer defects, with less human effort, less space, less capital,

June/July 2008 | industrial automation asia  27

software & Networks

MES Software:

Lean On

MES MES software has been embraced as part of Lean, yielding the benefits of continuous improvement, reduced waste, improved response times as well as optimised energy usage in support of addressing sustainability initiatives. By Gordon Benzie, Apriso Corp

ith today’s global economy and collaborative supply chain environment, it is no longer practical to run autonomous plants and warehouse facilities with a ‘silo’ approach to Lean. Too many processes are now dependent upon outside factors, such as shifting customer preference, quality or logistics bottlenecks. A tectonic shift within Lean manufacturing best practices is happening right now. Based on decisions implemented by ‘best in class’ manufacturers, Manufacturing Execution System (MES) software has been embraced as part of their Lean journey, yielding the benefits of continuous improvement, reduced waste, improved response times as well as optimised energy usage in support of addressing sustainability initiatives. While Lean manufacturing has 28  industrial automation asia | June/July 2008

been in vogue now for some 40 years, it continues to grow in importance, especially as new requirements and competitive pressures surface in the manufacturing arena. In the early years of Lean initiatives, companies made headway fixing shop floor and human-centric issues without ever touching IT systems. However, in today’s world of the globally distributed manufacturing organisation, with operations and processes that span continents, the business landscape has radically changed. And with these changes, manufacturers are coming to the realisation that software is now a requirement for distributed Lean manufacturing. The integration of software into a Lean programme has been identified as a best practice, providing a systematic framework for change management and continuous improvement, as well

as corporate sustainability, a growing concern among manufacturers. Software As A Requirement A recent sur vey conducted of manufacturers by Arc Advisor y Group found the adoption of Lean manufacturing increased by twofold over a recent 15 month period comprising the 2006 calendar year. In and around this same time period, their research on adoption of Manufacturing Execution Systems (MES) also showed a steep uptick, with a growth rate of 27 percent. Based on this high degree of correlation, manufacturers o p e r a t i n g i n t o d a y ’s c o m p l e x , dynamic and global manufacturing environment now recognise Manufacturing Execution System (MES) software plays a vital role in the success of a Lean manufacturing programme.

Making Lean Stick The first key to success in deploying and sustaining Lean can be found in a manufacturer’s ability to apply Lean methodologies across the organisation. “Despite attempts, most businesses have not been able to capture or sustain the benefits of a lean transformation,” says Paul Swift, a Lean consultant with BeyondLean in his introduction to his Step by Step Lean Guide. “Lean manufacturing represents a fundamental change and most businesses have pursued change in tactical, rather than a strategic manner … the methodology of many companies is to rely on a series of quick-hit approaches that deliver short term benefits, but aren’t sustainable in the longer term. Add to this the reluctance of many companies to consider the business as a whole rather than just concentrating on operations or manufacturing and you have a recipe for failure.” A winning approach to Lean is one that spans all dimensions of the manufacturing enterprise, encompassing all those involved in the value stream, from ordering through manufacturing to cash received.

MES supports the application of Lean best practices – adding value to Lean initiatives – by facilitating p ro c e s s e x e c u t i o n t h a t s p a n s multiple operations, aside from just production. This ability to infuse the organisation with embedded business processes also enables MES to address one of the most challenging aspects of manufacturing management and Lean – the enforcement and continued adherence to defined processes. Business Process Management (BPM) allows for complete control and monitoring of process execution and conformance. Phrased differently, while Lean techniques provide the methodology to optimise business processes, MES with BPM provides the ‘infrastructure’ to implement these efficiencies and sustain them on an ongoing basis. BPM tools provide modeling, simulation and orchestration capabilities that can be used to optimise business processes across the value-chain. By leveraging IT systems with embedded business processes, organisations can ensure process consistency across varying personnel, shifts, and facilities; this reduced variation in processes is a key tenet of continuous improvement programmes. Stated differently, ensuring new processes are embedded rather than manual helps to sustain higher performance over time, as indicated on Figure 1. Streamlining the process of instituting process changes and

refinements means companies can achieve greater success, as more improvements are implemented, rather than merely theorised, helping drive an efficient and successful Lean programme. There is no longer an acceptance of ad hoc business processes. Processes are deliberately planned and standardised to reduce waste, save money and create quality products and services. Processes are immediately and consistently implemented, and most importantly, these processes are able to be sustained over time. Accurate measurements and metrics are put in place and actions are taken based upon them. The success (or failure) of processes can then be assessed using quantifiable benchmarks. This is one of the key benefits BPM brings to the table – automated controls and data gathering about the performance of the process. The Global Enterprise In search of lower costs, faster times to market, and heightened product innovation, manufacturers are setting up operations overseas, and moving toward more global outsourcing strategies. However, integrating operations from plant to plant across borders can be tricky. Aside from the obvious language and localisation issues, global manufacturing adds an exponential layer of complexity and the need to navigate and adapt to ever-changing global market dynamics. Today’s emphasis on global Embedded Business Process


Defining Leadership When researching the findings further, it becomes clear that industry leaders successfully use technology to support their continuous improvement programmes, with Lean and Six Sigma chief among the continuous improvement programmes specified by respondents. More specifically, 77 percent of those surveyed reported their use of MES ‘accelerates’ their continuous improvement programme. When examining the findings in more detail, it becomes clear there are three categories where manufacturers see a critical function for MES, one that ensures their Lean programmes will be executed and maintained, generating current and future cost savings through process optimisation and the reduction of waste from operations.

Manual Businss Process

Begin Analysis

Time Identify Improvement

Change Complete

Figure 1: Embed BPM in Your MES & IT Systems

June/July 2008 | industrial automation asia  29

software & Networks sourcing and production is pushing manufacturing to a whole new level of Lean. For companies that have operations spread far and wide, o p t i m a l p e r f o r m a n c e re q u i re s frequent adjustments and relocations of operating capacity, as markets and supply sources shift. Lean manufacturing operations shift more readily. In today’s global economy, Lean leaders understand it is short-sighted to consider a Lean programme within the silo of just one location. Waste must be removed from as many processes as possible; these processes now extend across the supply chain, throughout operations a s w e l l a s a c ro s s d i s t r i b u t e d production sites. Visionar y Lean organisations think ‘outside the box,’ extending and integrating processes to drive Lean practices enterprise-wide, across operations – sales, engineering, product development, procurement, customer ser vice, and human resources – and across the globe. Implementation of Lean across the distributed global enterprise requires MES to help facilitate and streamline information and goods flow among plants, suppliers, distribution centers and customers. It provides a system that identifies, captures and replicates best practices across the enterprise with support for diverse manufacturing methodologies, geographies, cultures and markets, as well as continuous improvement programmes. Additionally, this information flow across the global manufacturing enterprise enables companies to address the strategic imperatives of governance, risk management and compliance as they are optimising business processes. Quality Control Traditionally, quality management applications were implemented s e p a r a t e l y f ro m E R P a n d M E S applications, but today manufacturers have adopted a more holistic approach that considers quality an integral 30  industrial automation asia | June/July 2008

An OES supports the application of Lean best practices and adds value to Lean initiatives.

element of core business processes versus a bolt-on strategy. Management of quality control in a Lean manufacturing system is key. In a Lean environment, the management of quality control shifts from an inspection-oriented approach to defect-prevention. This means inspection at every phase of the production process, from material purchase, delivery, inventory, and supply to processing, as opposed to the conventional manufacturing process of inspection at the beginning, during, and at the end of the production processes. To support quality control, data collection and reporting is needed to identify a star ting point for improvement and track progress as processes are refined. Many companies conduct data collection and reporting manually in an offline system (typically Excel) which generates waste in terms of time and effort, and also introduces opportunity for error. MES offers employees, supervisors and plant management visual realtime dashboards focused on Key

Performance Indicators (KPIs), that can be used to monitor the whole corporation, lines of businesses, functions or processes, with the ability to drill-down on any data point for the details. These systems can also notify users immediately when out-of-control conditions occur, so process owners and process specialists can capture the root cause for corrective action or for best practices implementation. This empowers the people who do the work with the right information to identify problems and take appropriate corrective action. A Holistic Approach MES has become an essential component of Lean manufacturing success in today’s world of complex global supply chains, ever-changing product mix and greater demand volatility. Yielding the benefits of continuous improvements, reduced waste, improved response times as well as sustainability initiatives, MES has been adopted by Leaders in Lean, integrating the needs of the real-time plant environment with the

transactional environment of business systems. But deploying an MES system is just a start. The reality is that Lean thinking must be deployed at more than just along the production line. Instead, manufacturers considering the bigger picture should consider integrating their warehouse operations, quality and even their maintenance operations execution with Lean. And, this integration should be accomplished across all locations, rather than just a few select plants or warehouses. An Operations Execution System (OES), such as the FlexNet solution provided by Apriso Corporation, can accomplish this challenge. It is only by looking h o l i s t i c a l l y a c ro s s t h e e n t i re enterprise can significant cost savings be achieved and maintained. An OES supports the application of Lean best practices and adds value to Lean initiatives, encompassing

Software is now a requirement for distributed Lean manufacturing.

processes that span multiple areas of operations. By efficiently establishing and maintaining business processes and the collection of operations data throughout production, the supply chain, warehousing and the

execution of maintenance management programmes, a more cost efficient continuous improvement programme is possible, saving time and resources to maintain and optimise. ENQUIRY NO. 4301

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June/July 2008 | industrial automation asia  31

software & Networks Rodolfo Clix, Sao Paulo, Brazil

Implementing an industrial Ethernet network that is cost effective, durable and reliable. By Daniel Santos, field application engineer, N-Tron Corp

Industrial Ethernet Network:

Best Laid Plans ffective network implementation requires thorough understanding of the project and the main objectives for the stake holders i n s i d e t h e o rg a n i s a t i o n . B a s i c project management skills that any project manager (PM) should have in order to implement a project in an industrial network include leadership, communication, organisational skills and technical experience. Tracking and understanding the project is absolutely instrumental for the project team—using guidelines such as systems development life cycle (SDLC) or a rapid application development (RAD) process would provide reliable tracking and project management throughout the project’s development. The stake holders, PM and team members should discuss the deliverables in detail. The deliverables may include a discussion of the planned industrial network topology, desired switches that will support the network requirements therefore meeting all the stake holders needs. 32  industrial automation asia | June/July 2008

Design Stage The design development and the preliminary testing phase is key for network engineers and designers. In this process the network engineers, system integrators, and developers would gather the plans from the prior meeting and replicate as close as possible the planned network, therefore trying to reach the desired goals of speed, reliability and redundancy. Other matters of discussion for the PM is to ensure that the users are trained, and the hardware is not difficult to manage therefore plug and play devices are excellent for industrial Ethernets as it provides ease of installation and management for all the users. By the end of this phase the engineers should be able to provide a detailed topology of the ring or desired topology with the details of connections and instructions on how to configure the switches on the industrial network or how to plug the equipment up if it’s just a plug and play device.

Gathering Feedback One of the biggest problems in the networking world is the lack of documentation of a network, therefore in an industrial network it is imperative that the network engineers documents all data in reference to the devices on the network. Some useful information would be the MAC addresses for all devices, IP addresses, ports where the devices are plugged into, configuration setting per device, types of connection and anything else that the engineers may think pertinent for troubleshooting the network on a later date. A maintenance phase which is a continuous phase must be put in effect. This phase allows the engineers maintaining the site to ensure that the network is working effectively and efficiently. If everything is completed including the user training the organisations would need to have an approval meeting with the entire team to ensure that all basis of the implementation of the project are covered such as checking for the completion of any

Key To Success When completing an implementation the PM must be closely involved in all the details to ensure that all the reportable deliverables are described in detail for the stake holder’s reports. In addition the team can validate the final implementation of the project via functional testing. Proper planning of a network change is imperative, to ensure the success of all contributors and stakeholders involved. Industrial Ethernet networks require reliability, availability, speed, robustness and the capacity to ensure that all data is transferred from a PLC’s to I/O’s without any interruptions as these interruptions may cause multiple problems, loss of revenue, cause bodily injury, loss of limb or even loss of life. Industrial networks require

equipment that is going to be durable, and perform data transfers at wire speeds, therefore the careful planning of a network and the involvement of the stakeholders, team members, users and project manager are crucial for any industrial network project. Proper research is imperative in the entire SDLC process form ensuring ease of use such as plug and play, good availability such as ensuring that the equipment has a large MTBF, and a detailed cost benefit analysis to ensure that your organisation gets the best product for the best price. Downtime cost can be extremely significant especially if the PM did not do the proper research on MTBF and availability of the devices—as therefore research shows: • Units per hour is another subfield used to calculate downtime at the machine/profit centre. It is important to use the units that would be produced if the machine was running at manufacturer’s

specified speed and capacity. This is a key area of potential savings as pointed out in the OEE section. • An example is high-tech gluers, which are all computer controlled, and provide speeds of up to 60 thousand units per hour with on line quality control. If your machine falls in the industry average OEE of 60 percent, that’s 24 thousand units per hour times the cost per unit, you are losing. Proper planning, communication and leadership is essential for the project manager to complete a good industrial Ethernet project and if following the proper SDLC process all parties involved will be successful in the achievement of the end state goal with a good industrial Ethernet network that will not only be cost effective but durable and reliable for many years. ENQUIRY NO. 4302


pending issues during the testing and formal testing phases.

June/July 2008 | industrial automation asia  33

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Batch Control:

Recipe For Flexibility Implementing a flexible solution to handle a large permutation of recipes and mixes, simplifying production while maintaining consistent quality. By Anna Russo, marketing coordinator and channel support EMEA, Wonderware


ritish Bakels is a supplier of baking ingredients. They operate f ro m m o d e r n p ro d u c t i o n facilities and offer their services to commercial bakeries and other food manufacturers. The company required a system that would simplify the production of hundreds of products whilst providing consistent quality. Located on a 5.5 acre site in Bicester, Bakels has invested over £15 million (US$29.6 million) in powder blending and wet production, and in warehousing. Production volumes exceeded 20,000 tonnes in 2005. Alongside its manufacturing is a bread assessment laboratory to support its key product groups of bread and roll improvers in liquid, paste and powder forms, release agents, divider oils, shelf life extenders, speciality bread mixes, confectionary mixes and glazes. Flexible Batching The production flexibility required by Bakels involves hundreds of raw 36  industrial automation asia | June/July 2008

ingredients and hundreds of finished ingredient products. The company is therefore placed in the centre of a business that requires flexibility and consistent quality with an overriding discipline of food hygiene and compliance with trade accreditation schemes. They have invested in equipment, tools and training that allow continuous business growth to be achieved. To provide smooth and effective operation it was foreseen that the company would need a solution that could flexibly handle the full permutation of recipes and mixes that they needed to process. First consideration was given to a wholly PLC based system but it soon became clear that this was inappropriate to the scale of the problem. Bespoke computer solutions were also dismissed as being an unacceptable business risk. Stratos Control Systems Ltd proposed a far more powerful and standard solution centred upon Wonderware’s InBatch

software system, following evaluation this was adopted. Top To Bottom Information The use of the InBatch software and other FactorySuite components is part of a comprehensive scheme that automates the entire business process. The company’s manufacturing plan is held with a Microsoft Dynamics Axapta MRP system which produces a daily schedule, the end result of which is pallets loaded with the required dry basic ingredients for the day’s production, wet ingredients being pumped automatically. The software system takes this schedule information and under the principle supervision of Simon Dawson, process engineer, produces step by step production instructions for operators and automation controllers. The process involves weighing, mixing, dosing, blending using a carefully controlled sequence of vessels for melting, dissolving, mixing and cooking. The many combinations of ingredients to make Bakels’ products are in this way easily handled without error and with the ability to produce high daily volumes from many differing orders. Production is arranged in lines, each having flexible operation and capacity to meet differing production demands. CIP is built in to the system and is also under full automatic control. The company has defined expansion plans to establish further lines within the same production area to support planned business growth, the efficiency and flexibility of the batching system contributing to the basis for the business model for this investment. Doing The Work The development of the system was done jointly by Bakels’ and Stratos’ engineers, with assistance in the batch management consultancy by Wonderware UK batch specialist Dr Geoff Brown. The architecture of the system involves dual server redundancy, Ethernet and wash-down Advantech touch screens on the plant itself. The system allows both manual

and automatic operation and quickly gained operator acceptance following in-house training. Consistent Quality Away from all this activity is Bakels’ product development laboratories, here new recipes are developed both speculatively and also at the request of bakers. Once developed, the production method has to be scaled up to deliver the same characteristics in volume manufacture. Products are formulated to suit each market sector and the company has teams that focus on serving the particular needs of each sector. Their operation is BRC level ‘A’ accredited (which was the subject of a recent audit by EFSIS) and the company has further accreditation as a Halal Food Authority approved supplier and by The Soil Association, as producer of organic products. Nick Luxemburg, Bakels’ engineering manager said: “The system

that has been installed provides us with major competitive advantage and the ability to deliver right on schedule.” Technology Focus The system consists of three servers, two running the InBatch software in a redundant configuration and the third server running Microsoft SQL for data logging. The servers are connected via a dedicated high speed Ethernet link to the production line HMI’s and the production line PLC’s. The servers also act as a secure gateway between the production network and the site network and Internet. This allows for remote access to all functions within the network including, diagnostics, upgrades and maintenance. If required the entire system can be securely remote controlled from anywhere by the Internet. T h e H M I s c re e n s a l l o w t h e operators to rapidly access large

amounts of information on the state of the production line. With the correct user login the HMI screens also give a clear but complete method of manually controlling the various aspects of the system. The InBatch software Active-X components of the HMI screen give easy access to the recipe control system. The PLC uses Profibus DP to communicate with the inverter drives and weighing stations. There is a bridge from the Profibus DP network to a Profibus PA network. This network contains field devices for monitoring pressure, temperature and conductivity. To further communicate with an existing tank farm installation CC link is use. The PLC also has four ASi networks containing both ASi 1 and ASi 2 devices. These control the process valves and other remote I/O devices. ENQUIRY NO. 4303

Encoders, actuators and positioning systems

Inductive sensors Precision switches My-com

Photoelectric sensors Ultrasonic sensors

Baumer (Singapore) Pte Ltd. Blk 21, Kallang Avenue #03-173 Kallang Basin Industrial Estate Singapore 339412 Phone: +65 6396 4131 Fax +65 6393 5091 Email: Website:

ENQUIRY NO. 633 614

Capacitive sensors

June/July 2008 | industrial automation asia  37

instrumentation & Measurement hermal imagers operate in the infrared spectrum and follow the same laws as infrared (IR) ther­m ometers, but the similarity ends there. IR thermometers report an average ‘spot’ temperature. IR thermal imagers are similar to digital cameras and, in practi­cal terms, may be thought of as infrared cameras. An LCD display shows a ‘movie’ of the IR image as the user selects the image, focuses, then pulls the trigger to record the image. In addition to highlighting temperature varia­tions and hotspots in real time through the


LCD display, some thermal imagers now include a technology that fuses a visual, or visible light, image with an infrared image for better identification, analysis and image management. Even with that, the power of thermal technology is not fully realised until the recorded image is downloaded to a computer, analysed with the provided software, and saved in a com­parative database along with descriptions, notes and an actual photograph to compare the IR with the visual image. Within the computer programme, the image can reveal specific spot

temperatures, a grid of temperature readings, minimum-maximum-average temperatures of a selected area of the image, emissivity and reflec­tivity can be adjusted, level and gain can be adjusted, the palette can be changed (colour, grayscale, or ironbow which is a smoother edged colour palette), and more. Thermal imaging is gaining an invaluable predictive and diag­nostic reputation in industries such as power distribution, plant maintenance, petro-chemical plants and process applications, to name a few.

Thermal Imaging:

olaroid rediction

Taking our visual sight capabilities beyond the visible spectrum to the radiated heat spectrum can alert us to processes that warrant further attention. By Bill Dove, HVAC systems trainer, Fluke

38  industrial automation asia | June/July 2008

An industry that is suited for thermal imag­i ng is the thermal dynamic industry of HVACR. Dynamic heat analysis of moving par ts (motors, bearings, sheaves, belts), electri­c al circuit quality (starters and contactors, disconnects, fuses and busses, electrical connec­tions), duct heat loss or gain, conditioned envelope heat loss or gain, tracing membrane roof leaks, compressor operating con­dition (relative head, sump, suc­tion, discharge temperatures and unloader or hot gas bypass oper­ ation), analysis of steam traps, radiators and convectors, radiant loops, or any process that can reveal the integrity of the process by comparative Fused power disconnect and corresponding infrared image. temperatures. The full range of HVACR applica­ tions for thermal imagers will only be temperatures through red-orangerealised once they are in the creative yellow-green-blue-indigo-violet to hands of HVACR technicians. black being cold. The gray scale palette also shows hot spots as white with Using A Thermal Imager diminishing temperatures through An HVAC technician interpret­i ng progressively darkening shades of a thermal image is similar to a gray to black being cold. This allows doctor interpreting X-rays or MRI’s. us to see a visible representation of This may sound ominous, but you the unseen IR spectrum. already have the HVAC knowledge What visibly looks like a disconnect and experience to know what you in good operating condition may be are looking for. Just add a few facts revealed as the L2 pole is operating about the nature of thermal imaging, 35°F (2°C) hotter (red) than L1 pole and you are home free. (blue). Equal loads, but different IR radiation is just beyond the temperatures. This disconnect has visible radiation spectrum. Radiated a problem that couldn’t be seen. Yet light is reflected off surfaces or emitted the thermal imager takes a ‘picture’ from sources that our eyes receive and of the entire device and its electrical our brain interprets. IR radiation is connections with comparative heat radiated by or reflected from temperatures. All real world materials a material; radiation that our eyes absorb, reflect and transmit IR cannot see. radiation depending on their physical Our skin is the best sensor of properties. IR radiation. We feel the radiation from a fire. We feel the radiation IR Radiation loss when standing close to a cold Whatever IR radiation is absorbed wall. A thermal imager interprets will be equally emitted. We do not IR radiated or reflected heat by encounter materials in the field that assigning a visible graduated colour perfectly absorb and emit all IR or gray scale to a radiated portrait of radiation. the scene. A material that absorbs all IR The colour palette displays hot radiation is called a ‘black body’ and spots as white with dimin­i shing has an emissivity of unity (1). Most

mate­rials of interest that we encounter are called ‘gray bodies’ since they are not perfect emitters; close maybe, but not perfect. Transmission through solids can usually be ignored in field work, with the exception being glass and plastic films which are referred to as ‘nongray bodies’. Emissivity & Reflectivity Reflectivity is inversely propor­tional to emissivity. The more an object reflects IR radiation, the less it emits. Reflectivity can be relatively judged according to our sight determinations of reflectiv­ity. Polished chrome has a very high reflectivity and low emis­sivity. Brushed stainless steel has less reflectivity and more emissivity. Tarnished brass and copper have even less reflectivity with proportionately more emis­sivity. Most painted surfaces have very high emissivity and negli­g ible reflectivity.

Air leak­age can be into the building, as in the cold air shown leaking through the floor, or out of it, as in the warm air leaking out alongside the chimney.

June/July 2008 | industrial automation asia  39

instrumentation & Measurement Qualitative vs Quantitative Most thermal imaging tasks are qualitative as opposed to quanti­ tative. Quantitative is accuracy of temperature, while qualitative is relativity of temperature. When viewing a contactor for instance, the interest is in the tempera­t ure difference of the 12 contact points. Are the electrical connec­tions all the same temperature (T1-L1, T2-L2, T3-L3)? Are the temperatures consistent between the fixed and movable contacts (T1C-L1C, T2C-L2C, T3CL3C)? Seeing one point of elevated temperature directs us to a poor electrical connection or failing contactor points without being concerned that the reported temperature is off by some percentage. P ai nt ed s ur f ac es ha ve h ig h emissivity and a very small margin of quantitative error. So our thermal image of a compressor, motor, bearings, steam traps, transformers, etc will tend to be fairly accurate without taking the steps to fine tune imager emissivity.

Thermal imagers offer a quick way to inspect equipment for abnormally hot-spots, and piping for abnormally cool spots.

40  industrial automation asia | June/July 2008

Adjusting Emissivity Thermal imagers have adjust­ments for both emissivity and reflectivity. Both are easy to mea­sure and compensate for when the need for quantitative readings outweighs qualitative readings. For emissivity adjustments, a strip of black electrical tape can be fastened to a surface and the taped and untaped surfaces can be measured with the imager. The emissivity is adjusted until the untaped surface temperature equals the taped surface tem­perature. For high temperature surfaces, a contact temperature probe can be used to measure surface temperature, then the emissivity can be adjusted until the IR temperature equals the contact temperature. Charts are also available which list the emissivity of various materials. Reflectivity Adjustments For reflectivity adjustments, a piece of aluminium foil is crumpled, then straightened and attached shiny side out to a piece of cardboard. Crumpling the foil creates a multifaceted surface to reflect radiation from all directions. The foil covered cardboard is held in front of the target to reflect ambient IR radiation. The reflectivity is adjusted until the temperature equals ambient air temperature. Reflectivity is usu­ally insignificant unless very high temperatures are being radiated in the vicinity of the target. Level & Gain Level and gain represent the expected target temperature (level) and the differential from target temperature (gain). If the level is set to 100°F (38°C) and the gain is set to 25°F (-4°C), then the temperature range would be limited to 75°F (24°C) to 125°F (52°C). Thermal imagers will automatically select the best level and gain of the target. Set at automatic, the imager displays the highest and lowest tem­ perature values in the scene. The minimum and maximum values of the scene define the extremes of the colour palette.

A white spot would not necessarily indicate a very high temperature, only the highest temperature in the scene. The highest temperature in one scene may be 90°F (32°C), while another scene may have a white spot indicating 250°F (121°C), if that is the highest temperature in that scene. The palette is proportional to the temperature range of the scene, not a fixed value. A slight relocation of the spot on the tar­get can change the gradient dis­play depending on the range of temperatures now in the scene. A semi-automatic setting will allow an upper temperature limit to be selected while the imager automatically and continuously recalculates the minimum scene temperature. High and low tem­ perature alarms can be set so that when temperatures approach the limits of reliability, the user can be notified graphically. Applications Of Thermal Imagers Thermal Imagers can be used for purposes where heat relation­ships are meaningful and provide very fast, multiple point tempera­t ure measurements of a scene. T h e y a re i d e a l f o r m o v i n g targets and machinery, hazardous and inaccessible or distant targets, electrical components, ‘big pic­ture’ evaluations of machinery or surfaces, trending records, and even protection against litigation and insurance claims. Keep in mind that thermal imagers measure surface tem­peratures only. The interpreter of the images must understand what is happening beneath those surfaces in order to make accu­ rate judgments. Temperatures of materials with differing emissivi­ties within a scene will not report temperature relationships equi­tably. Digital photographs of the same scene as the thermal image are useful not only for scene identification purposes, but also to identify materials of differing emissivities within the scene. ENQUIRY NO. 4401

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instrumentation & Measurement


emperature transmitters communicate digitally using protocols such as HART, Foundation fieldbus, and WirelessHART. Supporting this mix of transmitters can be a challenge. However, modern temperature transmitters diagnose themselves, the sensor wiring, and the temperature element. This allows for more effective maintenance schemes that help keep the loop and plant running with minimum downtime.

this, two sensors measure the same point. In normal operation the reading of one sensor is used, but if the primary sensor fails its value is discarded and the backup sensor reading is used. The transmitter diagnostics illustration is also helpful and allows the technician undertaking a repair or replacement to know whether it’s a field mounted, panel mounted, or head mounted device and what the device looks like.

p U

Temperature Transmitters:

Warming Enhancements to the EDDL IEC 61804-3 standards have improved advanced setup and diagnosis of high-end temperature transmitters. By Jonas Berge, senior PlantWeb consultant, Emerson Process Management Temperature Diagnostics A temperature element may eventually ‘burnout’, in which case temperature is not measured and control is impossible. This can cause the loop, and perhaps even the unit, to shut down. Intelligent device management software in modern control systems is permanently networked to continuously monitor field devices. When a sensor fails, the diagnostics pin-point the problem. Using EDDL (Electronic Device Description Language), the device manufacturer can provide image displays, switched dynamically, that illustrate the problem. High-end temperature transmitters have even more sophisticated diagnostics. Sensor ‘drift alert’ is one of the diagnostics available. A sensor with dual sensing elements at one measurement point takes two readings that are compared and if a maximum difference is exceeded, the diagnostics determines that drift has occurred. Another measurement available is ‘hot backup’. For

Temperature transmitter diagnostics indicate sensor failure.

42  industrial automation asia | June/July 2008


EDDL is the only technology that can display diagnostic detail directly to operator consoles showing failures that affect process operation. Predictive diagnostics are usually not routed to operators, and only go to maintenance technicians. Handheld field communicators are also based on the same EDDL technology, enabling further troubleshooting in the field while at the transmitter. Loop Testing Made Easy Loop testing a HART protocol temperature transmitter typically entails simulating temperature change by generating 4 mA, 20 mA, and 12 mA signals to check that the correct device is wired and system scaling is correct. Systems and software that fully implement IEC 61804-3 support EDDL wizards that take the technician through required steps to check the temperature transmitter as defined by its manufacturer. The wizard reminds the technician to inform the operators that a loop test will be performed so the associated control loop can be changed to manual to prevent upsetting the process when temperature is simulated. After the test, the temperature transmitter is returned to operational mode so measurements can again be transmitted to the control system. With EDDL, a loop test can be undertaken either from a control room computer or a handheld communicator in the field. Facilities have a mix of different temperature transmitters. Mastering all of them can be a challenge. However, the device manufacturers use EDDL to embed context-sensitive help into the display for parameters, wizards, and diagnostics. ENQUIRY NO. 4402


instrumentation & Measurement

Proximity & Presence Sensing:

The Fundamentals An introduction to proximity sensors and understanding the right selection for the right application. By Wong Ruting, engineer, Omron Asia Pacific

Operation Principle The three basic types of proximity sensors are: inductive, capacitive and magnetic. How does an inductive proximity sensor work? An inductive proximity sensor is made up of four components: detection coil, oscillation circuit, amplitude detecting circuit and output circuit. An electromagnetic field is produced by the coil at the front end of the sensor. When a metallic object approaches the electromagnetic field, an eddy current is induced in the object due to electromagnetis induction. As the target object continues to approach the sensor, induction current increases, which causes the load on the oscillation circuit to increase till a stage where it stops. The amplitude detecting circuit detects the change in oscillation status and triggers an output. The main advantage of inductive proximity sensors 44  industrial automation asia | June/July 2008

Sensing Distance vs Conductivity Graph

Iron Sensing distance (mm)


roximity sensors detect the approach of an object without making any physical contact. They are most commonly used in manufacturing equipment, robotic systems and many others for presence and absence detection and positioning. There are also special purpose proximity sensors for specific applications in areas like high temperature, welding, explosive, anti-bacterial and washing environments.

is that it detects only metallic objects such as iron, stainless steel, brass, aluminium and copper. The degree of change in the oscillation depends on the type of metal object. Hence, sensing distance varies with different metal objects. Sensing distance is longer for ferrous metals such as iron and stainless steel. This is due to the conductivity of the material itself. Ferrous metals have lower conductivity than non-ferrous metals (brass, aluminium, copper). Hence, ferrous metals offer higher resistance to induction eddy currents and disallow magnetic fields from penetrating deep inside the metal object. The greater the magnetic flux flowing out, the longer the sensing distance. Besides the object material, size, thickness of the object and effects of plating will also influence the sensing distance. Capacitive proximity sensors sense objects by directing changes in the capacitance between the sensor and the object. Capacitance is a property that exists between two conductive surfaces within a reasonable distance.

SUS Brass Aluminum Copper Conductivity of test object

General Guidelines In Selection Of Proximity Sensor Type of sensing object.

Required sensing distance. mm?

Whether it is shielded or unshielded.

Shape of sensor head.


Al, Cu

Direction of movement of sensing object.

Type of environment: subjected to oil, high temperature, cutting fluids, chemicals, vibration etc.

Output requirements: NPN/PNP, AC/DC power supply, response frequency etc.

Whether there is any interference, mounting constraints or other considerations.


PET bottles, plastic, liquids, powders, etc.

EcoLab or IP69K certified sensors are suited for sectors in the food, filling, packaging and pharmaceutical industries. They can be exposed to high pressure and aggressive cleaning and disinfectant agents. ENQUIRY NO. 4403

The Right Selection With the wide range of proximity sensors available in the market, it is sometimes hard to find the right sensor for the application. Hence, some general guidelines could save time and reduce the risk of wrong selection fit. Being clear on the application and requirements helps to narrow down the selection of sensors, aids application, improves production efficiency and reduces down time. New Applications General purpose proximity sensors are widely used in machines for simple presence and absence detection. With the need to cater to ever changing technology, a new proximity range has evolved with a new detection principle, special features and compliance standards to satisfy market demands. A new detection principle, based on pulse response detection, achieves longer sensing distance for aluminium or iron as compared to normal inductive types. Special features, such as spatter proof, anti-chip immunity, oil resistance or explosion proof, allow sensor usage in heavy works industries.

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Capacitance is changed when the distance between sensor and object varies. It is due to this change of capacitance that capacitive sensors can detect the position of the object. Sensing objects can be metallic or nonmetallic (plastic, glass, liquid, etc). Magnetic proximity sensors work by opening or closing the reed switch by a permanent magnet that comes near it. They are most ideal for detecting the opening and closing of doors.

June/July 2008 | industrial automation asia  45

instrumentation & Measurement

Proximity & Presence Sensing:

Looking Further With advancements in technology, expectations and demands of proximity sensors have and will continue to rise. The industry requires faster switching and more reliable sensors. By Alan Lok, product marketing engineer, ifm electronic

Switching force Angle of approach

Characteristics of travel

he first industrial solution to the problem of proximity and presence detection was the limit switch. This simple device is a mechanical structure which normally consists of a level and a switch. When the level makes contact with an object, the force on the contact will close the switch, completing the circuit and generating a signal. The simple structure is practical and workable. However, as production processes become more complex, and demand for more sophisticated sensing methods becomes inevitable, the creation of proximity sensors became a necessity. The simple structure of the limit switch (figure 1) restricts the switch 46  industrial automation asia | June/July 2008

application area. The angle of approach of the limit switch must be precise, with minimal room for mechanical deviation. The level action requires a switching force, and the spring action of the switch reduces the possibility of this technology being employed in high switching frequency applications. This encouraged the development of 100 percent electronic proximity sensors. This type of sensors utilises more advanced techniques in presence detection, while overcoming most of the shortcomings of limit switches. A Simple Sensor The basic structure of electronic proximity sensors is shown in figure 2.

Figure 1: Limit Switch

Electronic proximity switches require a small supply of electricity to power the electronic circuitry inside the switch. The first part (basic sensor) registers the change in the physical condition, the second part processes these information into signals to be used by either the programmable logic control or other controller devices. The three basic types of proximity sensors used today include inductive, capacitive and magnetic

proximity sensors. Each operate by different technology. Inductive makes use of changes in magnetic field. Capacitive, a change in the level of capacitance between the sensors and the target object, and magnetic sensors use a re e d s w i t c h t o m e a s u re t h e distance of the target object to the sensors. I n t o d a y ’s m o r e a d v a n c e d technology, the mechanical structure and principle of reed switching is becoming less relevant to the requirements of the industry. Now faster switching, more ‘reliable’ sensors, has enhanced the development of different working principles such as Hall Effect, induction and GMR (giant magneto resistance).

• Retro Reflective Sensor The transmitter and receiver are built into a single ‘compact’ housing, and a reflector is used to reflect the light from the transmitter to the receiver. When the object is present and blocks the light from reaching the receiver, the sensor will switch the output. • Diffuse Reflective Sensor Similar to retro reflective, however these sensors emit light, and the presence of the object is based on the reflection of the light received back from the object detected. When the object not present is missing, the light does not reflect back, hence the system will know when the object is present or not.

auxiliary supply



input signal

Figure 2: Sensor Structure

signal conditioning

signale preprocessing

(eg: filtering)

(eg: compensation)

basic sensor

signal processing

intelligent sensor

• Through Beam Sensor F e a t u re s a l i g h t g e n e r a t i n g transmitter device and a light sensitive receiver device. When the objects block the light between the transmitter and the receiver, the presence of the object is detected.

Advances In Vision Technology As light sensitive diodes and Cads only capture 2D images, a more advanced form of image capturing technology has been developed, known as the 3D sensor. In addition of the X and Y axis, this new type of sensor employs the ‘time of flight’ technology allowing the acquisition of extra Z-axis information. The real size and volume of the object can hence be determined.

output signal

parameter setting

Photo Electric Sensors As more advanced automation processes have been developed, different requirements have evolved. Sometimes, objects may not be in metal or the target distance may be too long for the inductive sensor to detect the object. Hence the development of photo electric sensors. Photo electric sensors or photo cells utilise light to detect an object. There are three major operating principles:

and computer systems, as well as advances in memory technology, the application for such a technology is now enormous. The complete vision and computer system can replace the human eye, acting as an artificial eye for qualitative purposes. It is capable of comparison, guidance and even accurate recognition. An example of a simple application can be as a form of quality control to ensure the object/product fits a certain specification in shape.

Vision Sensors Vision sensors have been developed to utilise light as a source of sensing. It is similar to the diffuse reflective sensor. However, it does not only detect the presence, but a pre-programmed image of the target object. These sensors feature powerful microprocessors to generate accurate, reliable results. Most vision sensors utilise a series of light sensitive diodes or CCD (charge couple device) sensors to capture the image of an object. Coupled with a microprocessor and advanced analogues to digital conversion technology, the image can be processed or stored as a digital signal which can later be retrieved with ease. Wi t h t h e f a s t e r p ro c e s s i n g speeds of current microprocessors

Future Technology Proximity and presence detection technology has come a long way and with the reduction in size o f m i c ro p ro c e s s o r s , a l l o w i n g an increasing level of artificial intelligence to be built in into a sensor. The most sophisticated types of inductive sensors feature advanced output options for analogue output when measuring not only position, but accurate distance information. New vision sensors feature higher resolutions and processing speeds, hence, identifying objects the normal human eye cannot see or catch due to the speed of production line movement. Proximity sensors have and will continue to become more ‘intelligent’, and will include fail safe circuitry for critical applications as well as remote adjustment capability, and real-time monitoring and control functionality. ENQUIRY NO. 4404

June/July 2008 | industrial automation asia  47

sector spotlight

Appetite For Expanding an F&B plant by increasing capacity, improving delivery punctuality and speed, and doubling picking and dispatch performance. By Han Kian Kwang, regional director, business development, Dematic he n S achse n m ilch AG , a dair y compa ny in the German market carried out a comprehensive plant expansion, in addition to increasing capacity, the goal of the project was to improve deliver y punctuality and speed, and to double picking and dispatch performance. This was achieved by a number of measures: optimising the distances travelled in paperless order picking, the use of a highly dynamic buffer shelf for provision of the picked goods for a specific order at the right time, supplying of the goods on 66 gravity feed conveyors as and when needed by the unloading stations, and innovative use of RFID technology. Every year, approximately 1.4 billion litres of milk are processed here to make milk, yogurt, fruit-based milk drinks, buttermilk, rice puddings, creams, butter and milk desserts. As part of the plant expansion, 48  industrial automation asia | June/July 2008

Dematic was engaged to supply the conveyor components, the IT system for warehouse management and material flow control, and also to handle the complete integration. As the management of the finished goods warehouse for dry substances must be one hundred percent reliable, it is imperative that a product and the batch it came from can be traced effectively. It must be possible to carry out this function efficiently and reliably in a manually controlled satellite warehouse. RFID To The Rescue To prevent any operating errors, systematic IT support for prompting the user is required. RFID provides assistance here through automatic locking of process steps that are not permitted. In the finished goods warehouse for dry substances, the storage and retrieval process is supported with

RFID in a manually controlled satellite warehouse with 2,600 positions. This is not only a more efficient solution for material transport but is also more reliable than solutions in the past. Each of the 420 individual channels is equipped with RFID tags, and the RFID reader is mounted on the forklift truck. The pallets themselves will continue to be marked with a barcode for the time being. The labelling of the channels with RFID tags is advantageous in this case since they are less prone to damage or soiling. An additional factor is that with front loading of the channel, the identification of a barcode is significantly more time-consuming because of the distance to the scanner and the time taken for aiming. Dematic has solved this problem by upgrading its own IT warehouse management system with the RFID-assisted processes, and by implementing it on the terminals on the forklift truck and integrating it with the RFID readers. When the pallet is received, the forklift truck reads the barcode to enable it to store the pallet in the warehouse. The transport order

generated by the warehouse administration system is carried out and automatically acknowledged by the RFID tag at the storage position. In this way the pallet is booked to the destination channel in the warehouse administration system. The position management in the warehouse management system makes it possible to see clearly at any time which pallet is in which position of the channel. Finding & Retrieving Re t r ie v a l i s ve r i f ie d i n a t wo stage process. Firstly, the slot is acknowledged via the automatic reading of the tra nsponder. To achieve the one hundred percent security demanded by food producers, the barcode label is then identified additionally with a u n ique ide nt i f ic at ion on t he pallet. This is necessary because manual storage processes cannot be ruled out entirely, especially in channels with free access from the side, for example in the case of damage to

The warehouse management system makes it The identification of a barcode is possible to see which pallet is in which position. significantly more time-consuming.

goods. This two-stage identification solution. The solution implemented indicates possible incorrect storage o f f e r s a v e r y h i g h d e g re e o f early on, corrects it and thus rules out flexibility and reliability within the this possibility. environment of a manually controlled The advantages of fast, troublewarehouse. free acquisition of the storage slot coordinates are a keySG-741-E2-000 factor in this 85x114 30.04.2008 16:36 ENQUIRYUhr NO. 4405 Seite 1

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June/July 2008 | industrial automation asia  49

sector spotlight

Green Packaging,



nvironmentally sustainable (‘green’) packaging is something consumers desire and mainstream retailers are beginning to require from their branded product manufacturers. And with good reason: green packaging conserves precious resources while reducing waste streams and total environmental footprint. In these days of increasingly expensive materials and heightened environmental awareness, what’s not to like? But from the point of view of the brand owner, it is not quite that simple. For most companies, meeting the definition of environmentally sustainable packaging means replacing current package designs with new, green designs. This is an enormous undertaking that will be seen as either another compliance mandate, or as a stimulus for broader process transformation with the potential for multi-million dollar shared returns. ‘Lean and green’ is the rallying cry for those who subscribe to the latter point of view. Wal-Mart’s experience certainly supports the lean and green view. In a USA Today article, Wal-Mart CEO, Lee Scott, talked about one of his company’s efforts to put products in ‘right size’ packages. “By making the packaging just a little bit smaller on one private brand of toys,” Mr Scott explained, “we will use 497 fewer containers and generate freight savings of more than US$2.4 million per year.” Creating Opportunities Customers frequently face customer-driven mandates and governmental regulations that specify certain product requirements. They require a product development environment that facilitates the continuous evaluation and balancing of these and other requirements, leading to product designs and programme decisions that deliver 50  industrial automation asia | June/July 2008

Money Tree

Balancing economic and environmental objectives in CPG and F&B packaging by employing best practices. By Chin Ying Loong, VP, ASEAN/Australia/ New Zealand and Daniel J Staresinic, global marketing director, consumer products, Siemens PLM

the desired profile of performance versus all recognised requirements. When we consider the enormous shift presented by the move toward environmentally sustainable packaging, we see yet another opportunity for customers to become successful in their perpetual rebalancing of ‘what counts’ in their brands. To facilitate a lean and green outcome, we propose that consumer packaged goods (CPG) and food and beverage (F&B) manufacturers consider the following best practices for packaging and the inevitable redesign task they face: • Improve Visibility The typical packaging supply network today is global, encompassing design, artwork, photography, engineering, pre-press, printing and manufacturing done by a myriad of suppliers located in disparate countries. It has become increasingly difficult to keep track of the various components, not to mention the intellectual properties and workflows associated with even relatively simple projects. A concerted focus on restoring visibility and transparency throughout the global network is thus a foundational requirement for efficiently going green. As a simple example, consider the use of recycled substrate. Asian suppliers use it routinely, but since not all United States mills are set up to run 100 percent recycled substrate, costs may be higher here. But then again, the higher price might be balanced out by other considerations. To make cost-effective green packaging decisions, it’s vital to consolidate resource and cost information from around the world and make it

available (for example, in a pack management dashboard with easily understood reports). This greater visibility exposes opportunities within the packaging supply chain that were previously hidden.

To facilitate a lean and green outcome, CPG and F&B manufacturers should apply some best practices for packaging.

Product Lifecycle Management (PLM) PLM provides direct support for the three best practices outlined above and, as such, it is a key tool for CPG and F&B companies choosing to address the topic of environmentally sustainable packaging. Brand owners have a lot of work to do to redesign and relaunch their packages to address the increased focus on environmental impact. But with PLM, this is an opportunity to deliver business value at every step of the process. Those who win biggest will be those who leverage such technology to effectively choreograph the overall flow of activity and decisions from idea to value. ENQUIRY NO. 4406


• Touch & Keypad Embedded HMI • Industrial LCD Touch Monitor • PC-Based HMI • RISC-Based HMI

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• Make Green A Requirement A wise man once said: “You get what you measure (whether you want to or not).” Therefore, if you measure green you will get green. But to sustain itself, measurement must be based on broader value. Greenwashing packaging will be found to be unsustainable. The same conditions that drive environmental waste often drive non value added costs, so the best practice is to define the packaging challenge as becoming lean and green. The institutionalisation of this perspective begins at the top, but needs to be enforced and reinforced by practices throughout the extended packaging management organisation. Such a culture of top-down green direction will be enabled by a portfolio management approach that exposes a balanced view of each packaging project, and that enables executive choices made about each project to be quickly transferred into execution. In this way both executives and designers will have conspicuous reminders that the objective is not green for the sake of green, but green for the sake of holistic value.

Zsuzsanna Kili·n,Budapest, Hungary

• Open Up The Innovation Network Today, final packaging is probably created by various suppliers who rarely, if ever, meet or interact due to geographic and linguistic barriers. That said, another best practice for lean and green packaging is turning this loose-knit confederation into a dependable, cohesive network charged with delivering the most innovative, cost-effective and compliant green packaging possible. As an illustrative example, consider the way various packaging suppliers must respond together to a common mission on behalf of a brand owner. In a traditional scenario, the handoffs between suppliers will be mostly sequential, and probably gated by the brand owner. But in a global innovation network, the collaboration ‘backbone’ provides a secure means for them to collaborate freely. They are able to share best practices among themselves to develop a true competitive advantage for the brand owner. It might be possible, for instance, for the artwork supplier to make a small change that allows a printing process that uses biodegradable ink. But this is only realised when the artwork supplier, the ink supplier and the printer are free to collaborate in a secure, accelerated manner. What could be better than a motivated base of skilled suppliers working together to prove their combined competitive advantages to the brand owner?

June/July 2008 | industrial automation asia  51

design focus

Collaborative Engineering Through

Collaborative engineering as an area of strategic and functional innovation in the engineering world aims to provide concepts, technologies and solutions for product development. By Denis Branthonne, regional director, ASEAN, Autodesk Asia

Integrated Design

n today’s increasingly digitalised and globalised world, dispersed engineering teams working on projects are increasingly becoming commonplace. Witness how networked organisation structures have proliferated, for example, the virtual organisation, or networks of small and medium businesses working together, or enterprises with multiple 52  industrial automation asia | June/July 2008

bra nches. These structures are becoming common practice in many industries like automobile, aerospace, electronics or construction. Collaborative engineering as an area of strategic and functional innovation in the engineering world aims to provide concepts, technologies and solutions for product development. There is expanding industrial demand

for this approach, and has become a key issue for agile and flexible engineering processes. There are many challenges in establishing collaborative engineering practices; the progression involves literally a continuum of improvements encompassing not just the integration of teams, processes and workflows, but also the unification of heterogeneous

The benefits of leveraging digital prototypes rather than physical prototypes are clear.

engineering ontologies, underlying domain models, and even different branches of engineering as projects and product needs become increasingly complex. In the engineering or product design space, digital design innovation technologies that enable the integration of digital models and workflows are an important step towards the ‘nirvana’ of a collaborative engineering environment. Typically, problems and conflicts between one engineering component and the other are discovered for the first time on the manufacturing shop floor. Time and money must then be spent to resolve these conflicts— two assets that most manufacturing companies today cannot afford to spare, given constant pressure to cut costs and delivery times. Mechatronics & Integrated Design The mechatronics approach is a good way to demonstrate the contribution of digital design innovation technologies toward collaborative engineering goals. Mechatronics is commonly defined as the synergistic combination of mechanical, electrical, and software engineering, all integrated through the

design process. Basically, electrical engineers, mechanical engineers and software engineers who often operate parallel to one another, can benefit, even when working on designing the same machine. Gaps that have historically existed between different engineering disciplines must increasingly be integrated with the design information i n t o d i g i t a l p ro t o t y p e s w h e re inefficiencies and design errors can be resolved digitally, eliminating the need to build expensive physical prototypes. The benefits of leveraging digital prototypes rather than physical prototypes in the design and manufacturing process were documented by industry research firm, Aberdeen Group. They examined and determined that those companies deemed to be best-in-class manufacturers tended to build only half the number of physical prototypes than the average manufacturer did and get products to market 58 days faster with nearly 50 percent lower prototyping costs. Collaboration In Mechatronics In mechatronics, a proper strategy to infuse collaboration capabilities at the design level should begin with the

utilisation of design technologies that have two key characteristics: First, each design technology should be purpose-built for a specific engineering discipline purpose. The second key feature is that each design technology should be tightly integrated with other design technologies in the design tool ecosystem. This combination of ‘purposebuilt’ with ‘seamless integration’ features is a critical component facilitating collaborative engineering goals, especially in industry segments where customisation is the order of the day, for example, the transportation industry. One benefit is the enablement of intelligent automation in the design integration process. Another key component facilitating collaborative engineering goals are integrated data management tools or services that combine all electrical and mechanical, 2D and 3D design data into a single Bill of Materials, allowing the full design intent to be leveraged throughout the lifecycle of the digital prototype.

Manufacturers will be able to design a machine and see how it operates before they’ve cut a single sheet of metal.

June/July 2008 | industrial automation asia  53

design focus

Innovation includes incorporating the latest in electronic controls technology, new materials, and manufacturing process technology.

By leveraging digital prototypes, this tight integration of mechanical and electrical information allows users to collaborate more effectively to create more accurate 2D and 3D mechatronic designs in less time, as integration and automation capabilities help to reduce errors and spot design problems earlier in the process. Innovate Or Stagnate In an increasingly competitive and global market, companies need to have the ability to increase the competitiveness of their products through the use of technology and must be able to respond rapidly and effectively to changes in the marketplace. The principles behind efficient coll a b o r a t i o n i n m e c h a t ro n i c s mean that it is rapidly becoming a requirement to meeting the innovation demands of manufacturing design customers. Through better collaboration capabilities, mechatronic strategies save manufacturers time and money. They have been shown to support and enable the development of new products and markets, as well as through enhancing existing products, while responding to the introduction of new product lines by a competitor. Companies can spend less time worrying that electrical component A and mechanical component B will 54  industrial automation asia | June/July 2008

fit together—and spend more time innovating. From a collaboration standpoint, the principles behind Autodesk’s mechatronics strategy are enabling innovation beyond ‘just’ introducing new products; it is about innovating new ways to collaborate with suppliers, to manufacture products, and even to co-develop products with customers. Innovation includes incorporating the latest in electronic controls technology, new materials, and manufacturing process technology. Ultimately, innovation is about being able to provide products and services to customers to drive top line growth,

while reducing costs to drive bottom line growth. Looking at mechatronics as a model of this innovation process, the mechanical and electrical engineering disciplines are working together more seamlessly than ever before. Autodesk is engaged with the next step - to bring software engineering - the third major component of mechatronics - even tighter into the fold, enabling complete machine simulation. Complete machine simulation will allow companies to utilise a digital prototype environment to test out not just the electrical and mechanical components, but also the software that runs it—the programmable logic controller. As a result, manufacturers will be able to design a machine, turn it on, and see how it operates—all before they’ve cut a single sheet of metal. The principles behind this ultimate vision in mechatronics facilitate collaborative engineering goals and have a wider application, by enabling engineers of all stripes, their stakeholders, partners, to visualise, simulate and analyse their work to an amazing degree of sophistication and to experience it before it all becomes real. This is a key advantage to ‘future proofing’ the capabilities of manufacturers in a global environment that demands innovation at an everaccelerating rate. ENQUIRY NO. 4501

Leveraging digital prototypes allows users to collaborate more effectively to create 2D and 3D designs.

products & Services Adlink: PCI Analogue Output Card

Baumer: Ultrasonic Sensor

Adlink Technology Inc’s PCI-6202 is a four channel, 16 -bit resolution analogue output (AO) card featuring a differential non-linearity of less than one least significant bit (DNL < 1 LSB). It provides multiple programmable I/O options: digital I/O (TTL), general-purpose timer/counters, motor encoder inputs, and PWM (pulse width modulation) outputs. A linear position trigger is provided for encoder input, whereby when the encoder counter reaches a preset value, an interrupt or trigger signal is generated.

Baumer’s miniature ultrasonic sensor Sonus has a housing of 10 x 14 x 27 mm and weigh less than four grammes. The scanning range is 200 mm, for the digitally switching proximity sensors and retroreflective types and also for the distance measuring versions with analog voltage outputs. The desired switching points and scanning ranges of the sensors and the polarity of the 0...10 VDC analog output can be adjusted to any conceivable application.

Enquiry no. 4601

Enquiry no. 4603

Advantech: Industrial Panel PC

GE Fanuc: Production Management

Adva ntech’s I PPC - 6152 A 15” XG A T F T LCD Industrial Panel PC has a 2 GHz Intel Pentium M processor, a front-accessible USB design, a DDR2 memory bus that supports up to 2 GB, a slim CD-ROM drive, and two PCI expansion slots. It is designed with a flat-sealed front-panel. The control box has the gull-wing design for easy component installation and maintenance. For user interface considerations, the front-access USB 2.0 port is NEMA4/IP65 compliant. It provides multiple standard communication ports (dual Ethernet LAN’s, and five USB 2.0 port).

GE Fanuc Intelligent Platfor ms’ Proficy Tracker 7.5 delivers lean production by helping to manage inventory, schedule resources in real time, and route material through the discrete manufacturing process. It provides the ability to track the real-time location of orders on the production floor. It can help companies to monitor and manage production flow through the use of business rules, dynamically collect and store a variety of data about each component and assembly to create traceability records, provide control commands to production equipment in order to process and route materials and support inspection and rework processes, as well as production, assembly, and packaging operations.

Enquiry no. 4602

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Enquiry no. 4604

products & Services

Harting: Ethernet Switch

ICP DAS: Ethernet I/O Module

H a r t i n g ’s m C o n 10 0 0 product line enables network solutions where t he ava ilabilit y of the facility is a high priority. The managed Ethernet switch supports Ethernet (10 Mbit/ sec), fast Ethernet (100 Mbit/sec) and Gigabit Ether net (1000 Mbit/sec). Up to 11 Ethernet stations can be connected with shielded twisted-pair cable and fibre-optic cable. The mCon 1052-ASFP and mCon 1083-ASFP Ethernet switches make it possible to adapt the application’s fibre-optic interface with the appropriate plug-in modules (eg SFP modules).

T he E T-70 52 , a we b - b a se d Ethernet I/O module, features a built-in web server which allows configuration, I/O monitoring and I/O control by using a regular web browser. The module supports Modbus/TCP protocol. It contains 8 - cha n nel isolate d source ty pe open collector outputs a nd 8 -channel isolated digital inputs with 32-bit counters. The module contains 2-way isolation from noise and surges, one for digital inputs and the other for Ethernet. The ET-7052 has got a range of power input of 10~30VDC and operating temperature of -25°C~+75°C.

Enquiry no. 4605

Enquiry no. 4607

Hoerbiger: Automatic Drain Valve

Igus: Vertical Energy Chains

Hoerbiger O r iga’s f loatcontrolled, automatic drain va lve c a n b e operated in the pressure range of 0.8 to 20 bar and in an ambient temperature of up to 120°C. These automatic drains have gone through an endurance test with one million switching cycles (at five bar). Due to its compact design, the automatic drain can be used independently but also as a completely combatible system component for the tried-andtested A50 airfit series (1 1/2 to 2 inches), the A25 series (3/4 to 1 inch), and soon the new A15 series (1/2 inch). A slight modification also enables the airfit drain to be used in conjunction with the widely used airfit swing series (1/4 and 3/8 inch).

The igus GmbH ‘Guidelok’ system is for vertical energy chain applications with large lifting heights. Compact and easy to install, also as a retrofit system, it makes energy and data transfer safe. The chain is suspended in a stainless steel or galvanised steel guide channel. It always remains safely on track even with mast or tower heights of up to 80 metres. Each part of the energy chain is automatically fixed in place by the rocker arm mechanism as it runs through the groove.

Enquiry no. 4606

Enquiry no. 4608

June/July 2008 | industrial automation asia  57

products & Services

Moxa: Terminal Server

Omron: AC Servomotors/Servo Drivers

Moxa has released the CN2600 terminal server series which is armed with dual network redundancy and offers data communication backup. The ‘Redundant COM’ mode of the series is specially designed for redundant connection between serial devices and a host computer. Employing the two built-in LAN ports on the CN2600, the host computer connects to the terminal server via two independent LANs. If one LAN fails, data will continue to be transmitted between the serial devices and the host using the other LAN.

Omron’s Omnuc G series AC Servomotors/Servo Drivers is designed for a wide range of applications requiring position control, speed control and torque control. The series offers a wide variety of servomotor capacities, ranging from 50W to 7.5kW with 2,500 pulse incremental encoders and high-resolution 17-bit absolute/incremental encoders as standard models for greater accuracy. Features include realtime autotuning and adaptive filter functions that automatically performs complicated gain adjustments.

Enquiry no. 4609

N-Tron: Industrial Ethernet Switches

N-Tron’s 700 Series switches are fully managed and come standard with: IGMP snooping, VLAN, QoS, trunking, port mirroring, RSTP, DHCP, and N-Ring technology. T he s w itc he s a l s o o f fe r we b b row s e r management and N-View OLE for process control server software. The N-View OPC server software can be combined with popular HMI software packages to add network traffic monitoring, trending, and alarming to any application using N-Tron switches. Enquiry no. 4610

58  industrial automation asia | June/July 2008

Enquiry no. 4611

Omron: Proximity Sensor Omron’s E2V-X Proximity Sensor has a ‘chip immune’ function that enables long-distance detection of Aluminium and Iron. This proximity sensor applies a detection principle called ‘pulse response detection’ which detects the transient response of eddy current caused by pulse magnetic field from sensor. With this, the sensor is less influenced by ambient temperature. Other features include 360 degree indicator LED and ‘smart-click connector’ for smooth and faster maintenance. The sensor is suitable for industrial application in automotive parts, machine tools, steel making and Aluminium construction.

Enquiry no. 4612

products & Services products & Services

Panasonic: Image Checker

Vega: Level Switch

W i t h P a n a s o n i c ’s PV500 Image Checker, image transfer, image processing, arithmetic processing and display processing are pipeline (parallel) processed with each respective processor to enable high-speed performance with an inspection execution time of 90 microseconds. High definition inspections are made possible by connecting four cameras from a mixture of three types of digital cameras including a quad-speed 300,000 pixel camera and a two-megapixel camera. The image checker also features a free layout function which allows customers to tailor the screen layout to their own needs. Up to 32 screens can be prepared. Enquiry no. 4613

A tuning fork is used as sensor for the VegaWave series measuring limits in bulk solid applications. It operates at a frequency of approximately 200 Hz. Adjustment with medium is not required. It detects light bulk solids, even those down to 8 g / l . T he robu st construction also makes it possible to use it in very heavy media, especially as eg an empty detector in high silos. And it is just a s insensitive to b u i l d - u p a s i t i s to statically charged products. Enquiry no. 4615

Raytek: Infrared Thermometer

Yokogawa: Network-based Control System

The Raytek XR sensor is a rugged, IP65 sealed single-piece system. It combines multiple extended temperature ranges, precision temperature resolution, RS485 outputs and an electronics platform. The sensor provides a flexible, user defined analogue output that can be matched with almost any existing control system. An intuitive local user interface simplifies system setup and configuration and adds troubleshooting capabilities.

Yokogawa Electric Corporation has an enhanced version of the Stardom network-based control system that complies with US gas industr y standards and provides a new data-logging function for the FCN/FCJ autonomous controllers. The enhanced version supports the American Gas Association’s AGA3, AGA7, and AGA8 standards used in North America, South America, and Asia. It provides both gas metering and control functions.

Enquiry no. 4614

Enquiry no. 4616

June/July 2008 | industrial automation asia  59

EVENT review

Hannover Messe 2008

Deutsche Messe Hannover

Deutsche Messe Hannover

The world’s leading industrial trade fair, Hannover Messe, took place with key themes of energy, automation, future technology and young engineering talent. April 21 – 25, 2008 Hannover Fair Grounds Germany

60  industrial automation asia | June/July 2008

event. Overall, visitor survey findings revealed that a total of some 3.2 million business leads had been generated during the event.

Deutsche Messe Hannover

t this event held in late April of this year, visitor numbers surged to around 200,000 — an increase of approximately 30 percent over Hannover Messe 2006 as the most recent edition of the fair of similar scope. “Hannover Messe is once again captivating the crowds,” reported Deutsche Messe managing board chairman Sepp D Heckmann at the endof-show press conference. Referring to the uniqueness of the event, Heckmann underscored its many different roles, for example as a barometer for the economy as a whole, a herald of future trends, a technology transfer platform, a forum for inventions and innovation, a knowledge hub and a driver of new cooperative ventures. An analysis of the fair’s attendees revealed that all primary targets had been met: Trade visitor numbers climbed by about 25 percent to just under 180,000, with a total of

approximately 127,000 decision-makers in attendance — an increase of around 20 percent. The event consisted of 10 international flagship trade fairs. The 5,100 participating exhibitors from over 60 different nations offered an impressive demonstration of the industrial state of the art. Almost all companies represented at the show reported generating many more new leads — on average around 15 to 20 percent more than at the previous

World Energy Dialogue Recognising the rising worldwide energy demands and the need to satisfy these demands, one of the focus points of this year’s fair was Energy. Encompassing four halls, the energy theme also included the World Energy Dialogue. This third global energy summit served as a platform for leading experts worldwide to pose questions - and propose solutions - relating to the vital energy issues of our times. By 2030 the International Energy Agency (IEA) predicts an increase of 50 percent in the level of primary energy demand. "Providing the additionally required quantity represents a gigantic task. We will need to build a sustainable bridge to get from our current economic


Conveniently located in the central part of the fair ground, the architecturally modern convention centre served as the venue for events such as the WoMenPower 2008 Congress and the International Siemens Press Conference.

Deutsche Messe Hannover

Deutsche Messe Hannover

This year’s Hermes Award was won by Zenergy Power Co in conjunction with Bültmann GmbH for its development of an innovative induction heater. Seen as one of the world’s most coveted industrial prizes, the award is worth €100,000 (US$154,600)!

The field of Robotics was a prominent feature of the event with companies like Kuka showing off their latest robotic arms and the RoboCup German Open, which provided plenty of smiles per robot.

Highlighting the growing importance of wireless communication, a section dedicated to wireless automation displayed technology such as Bluetooth, Zigbee and WLAN. A speakers’ corner served as a well of information, with topics such as wireless device networking and wireless data collection being discussed.

Deutsche Messe Hannover

Partner Country This year’s partner country was Japan. About 150 Japanese companies and organisations presented their products and technologies in areas like the environment, energy and robotics. Hannover Messe 2009 will take place from 20 to 24 April. The event is scheduled to include 14 international flagship tradeshows - this year's 10 shows, plus the cyclical reappearance of Motion, Drive And Automation, Surface Technology and Comvac. The Wind trade fair will also premiere in 2009 as part of the Energy event. The official partner country of Hannover Messe 2009 will be the Republic Of Korea. ‘The Beat Of Innovation’ has been adopted as the official slogan.

At The

Deutsche Messe Hannover

models to a low-emission future," declared Jürgen R Thumann, president of the Federation of German Industries (BDI). Mr Thumann sees Germany in a leadership role in the use of renewable energy, demanding a concerted modernisation drive for all forms of energy generation as well as the upgrading of networks for enhanced energy efficiency. "It is a joint challenge to the industrial as well as the emerging nations to accelerate our transition to low-emission energy providers," stated Dr Antonio Pflüger from the International Energy Agency. Despite dif ferent policies and technological approaches, this position achieved a broad consensus among the audience of leading industrial representatives from around the world. The focus of the third World Energy Dialogue conference was on the energy-efficient upgrading of power plants and networks against a background of acute climate protection challenges as well as the growing energy appetites of markets like China and India.


June/July 2008 | industrial automation asia  61

EVENT review

Beckhoff: Bus Terminal The Beckhoff KM6551 wireless terminal enables various types of transmission, based on the IEEE 802.15.4 standard. It exchanges data wirelessly at a gross rate of 250 kbit/s. The radio technology supports bidirectional data exchange between a master and one slave (peer-to-peer), a master and up to four slaves, and unidirectional data transfer from a master to n devices (broadcasting). Radio transmission takes place with 10 bytes of user data, independent of the bus system used. A diagnostic system integrated in the KM6551 enables monitoring of the radio link.

Bosch Rexroth: Miniature Linear Modules

Rexroth has expanded its portfolio of ready-to-install linear motion systems, adding miniature linear modules MKK and MKR in size 12-40 to the range. With identical connection dimensions and the same range of accessories and attachments, the modules offer users a choice between two drive options: ball screw drive (MKK) and toothed belt drive (MKR). Rexroth supplies these modules in length increments of one millimeter up to a maximum length of 1,000 mm for the ball screw version and 2,500 mm for the toothed belt version.

Bürkert: Liquid Flow Controller Bürkert’s liquid flow controller integrates sensors, control electronics and actuators into a single device. Configuration and diagnosis are possible via the serial interface with the ‘mass flow communicator’ software. LEDs displays the status and it has configurable binary inputs and outputs. An integrated totaliser allows consumption analyses. It is available for various control modules (analogue/digital via fieldbuses or RS232/RS485). Furthermore, a protection type IP65 available for applications in rough environments.

Lenze: Frequency Inverters The 8400 frequency inverter series from Lenze comes in three scaled funcationality versions: BaseLine, StateLine and HighLine. All versions feature the same simple handling, operation, programming, logistics and servicing. They have an overload capacity of up to 200 percent and a permissible ambient temperature of 45°C without derating. The versions StateLine or higher additionally support thermal control cabinet optimisation through push-through or cold-plate mounting options. 62  industrial automation asia | June/July 2008


EVENT review

Pepperl + Fuchs: Pressurised System The pressurised enclosure type of ignition protection enables non-Ex capable standard devices to be operated in hazardous areas. The Series 6000 can be used in applications classified in accordance with ATEX, as well as those classified in accordance with UL. The setting of the required parameters is accomplished using a menu-driven user interface. The selection of different purge control systems for different applications is no longer required. With the Series 6000 one device is available for all these different parameters. The different volumes of the pressurised enclosures can be set using the menu-driven user interface, which is also password-protected.

Phoenix Contact: Industrial Security Solution With the FL MGuard RS Firewall, Phoenix Contact provides an industry firewall/router solution for individual protection of distributed automation systems. The security devices in the ME45 housing can be mounted on DIN rails and are integrated in the network as an independent system. There, they protect a part of the installationâ&#x20AC;&#x2122;s network or an individual automation component without affecting the system to be protected. All inbound and outbound data packets are monitored based on predefined rules.

Sick: Safety Controller The Flexi Soft safety controller from Sick AG consists of a CPU that is expanded by plugging in I/O modules and gateways. Configuration takes place via a particularly intuitive user interface. The CPU, optionally also available with two integrated EFI interfaces, is designed for the connection of 12 Flexi Soft modules, so that the system limit is defined as 96 inputs and 48 outputs. Multi-channel input and I/O mixed modules, relay modules and fieldbus modules (for integration in the standard controller) are available.

Siemens: Compact Soft Starter Siemens Industry Automation is expanding its range of Sirius soft starters with the compact Sirius 3RW30. The devices in four frame sizes enable soft starting of motors in standard applications such as pumps, conveyor belts, or fans up to 55 kilowatts at 400 volts. The Sirius 3RW30 soft starter improves the startup characteristics of motors with two-phase polarity balancing, and avoids mechanical loads, voltage fluctuations, and current peaks. The user can set the startup time and the starting voltage using two potentiometers on the device.

64â&#x20AC;&#x192; industrial automation asia | June/July 2008


EVENT review


Malaysia 2008 The first ever Automex Malaysia event attracted over 200 companies who showcased the latest in automation products and technology.

Aleksander Cvetanovic (R) and Tan Meng Ho (L) of Kuka.

he inaugural Automex Malaysia, Malaysia’s international exhibition on automation technology and solutions was held in conjunction with MetalTech Malaysia in early May of this year. Albert Lai, MD of organiser Premier Exhibition Services said: “The plan to launch an exhibition on automation technology was incepted in response to interest from industry players through our exhibitions for the manufacturing, metalworking and woodworking industry. This has also been spurred by government incentives to automate. Implementation of leading edge automation will augment competitiveness, value creation and productivity.” In 2007, the Malaysian government allocated funds amounting to RM750 million (US$231 million) in the form of easy loan schemes for development and modernisation of the automation and automotive industry. The loan schemes are to encourage companies to modernise and adopt automation 66  industrial automation asia | June/July 2008

Dr Tan (L) and Mr Chung (R) of SIAA.

for their manufacturing processes. This includes increasing their production capacity and reducing their dependency on labour and foreign labour intensive activities as well as for the rationalisation of their operations. At the event, over 200 companies showcased a wide range of equipment on process automation, factor y automation, instrumentation and control, bus and wireless technology, hydraulics and pneumatics and robotics. One exhibitor was Kuka Robotics, who re-enforced their position in Asia and in particular Malaysia, where they have been present since 1992. Key product manager Aleksander Cvetanovic was at the event, giving a speech on ‘Better Quality Efficiency And Cost Savings With Robots For The Metal Industry’. Incorporated into the exhibition was an ‘Automation Week’, where a host of activities dedicated to automation including seminars,

conferences, forums and business matching sessions were conducted. One speaker, Dr Tan Guan Hong, president of Singapore Industrial Automation Association (SIAA), commented: “With the changing economic structure, the automation industry must innovate and transform towards better productivity, cost efficiency and service standards. Machine-to-Machine (M2M) communication enabling technologies would be the future of the automation industry for enterprises to gain the competitive edge.” Another speaker, OJ Chung, vice chairman of M2M consortium, SIAA added: “Technology is transferable. M2M as a unification of technologies and applications deliver numerous benefits to the operator, empowering the operator in real time.” Putra World Trade Centre Kuala Lumpur, Malaysia May 7 – 11, 2008 ENQUIRY NO. 4702

CalendarOf Events2008 JUNE 4 – 6 Asian Elenex 2008

Hong Kong Convention & Exhibition Centre Hong Kong Exhibition Services Ltd Email: Web:

4 – 7 Entec Pollutec Asia 2008 & Renewable Energy Asia 2008

BITEC, Bangkok, Thailand CMP Media (Thailand) Email: Web:

5 – 8 Manufacturing Hanoi 2008 Hanoi International Centre For Exhibition Hanoi, Vietnam Chan Chao Int’l Co Ltd Email: Web:

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15 Advantech Solution Day

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NOVEMBER 20 – 23 Metalex 2008, Thailand

BITEC, Bangkok, Thailand Reed Tradex Email: Web:

SEPTEMBER 9 – 12 Globaltronics 2008

Suntec, Singapore Reed Exhibitions Email: melanie.mostafa@reedexpo. Web:

17 – 19 Industrial Automation Vietnam

Ho Chi Minh City Int’l Exhibition & Convention Centre (HIECC) Ho Chi Minh City, Vietnam Hongkong Exhibition Services Ltd Email: Web:

NOTES To be considered for inclusion in the Calendar of Events, send details of event (name, date, venue, organiser contact) to: The Assistant Editor IAA. Eastern Trade Media Pte Ltd. 1100 Lower Delta Road, EPL Building #04-02, Singapore 169206 Tel: (65) 6379 2888 Fax: (65) 6379 2805 Email:

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