Automation World: Product Selection & Applied Technology Handbook 2021

PRODUCT SELECTION & APPLIED TECHNOLOGY HANDBOOK 2021

06 Assessing HMI Hardware Options 08 How to Select HMI Software 10 Which SCADA System is Right for You? 12

Ensuring a Successful Automation Migration Project

14 Single Pair Ethernet Explained 16

Want Better Performing Equipment to Stay Ahead of the Competition?

19

How Automation Advances Affect OEE

AW2104_Handbook.indd 1

3/26/21 3:14 PM

5DWHG RXW RI E\ FXVWRPHUV MXVW OLNH \RXđ

7HQV RI WKRXVDQGV RI KLJK TXDOLW\ ULJKW SULFHG LQGXVWULDO DXWRPDWLRQ FRPSRQHQWV DW \RXU ILQJHUWLSV • • • •

PLCs & HMIs Motors/Motor Controls/VFDs Field I/O Process Control & Measurement • Discrete & Analog Sensing • Motion Control • Pneumatics

• Pushbuttons/ Switches/Lights • Circuit Protection • Power Products • Enclosures • Safety Components • Cable & Wire • And Much More!

Does your supplier know their customer satisfaction score? If not, then maybe you need a new supplier!

“Whenever its time to start a new project the first place I go is Automation Direct. It’s incredibly easy to search for parts and I know that I’ll always be able to find what I need. I love Automation Direct!”

Martin in EL DORADO, KS “Very happy with the products and service. Automation Direct is my 1st choice when purchasing automation components.”

Arend in BONHAM, TX “The best customer and product support I’ve experienced with any type of supplier hands down. Product diversity, availability and value that is unmatched in the industry...”

Paul in JACKSON, MI Check out our vast selection of over 25,000 high-value automation components and all of our customer reviews at:

www.automationdirect.com

Order Today, Ships Fast! * See our Web site for details and restrictions. © Copyright 2020 AutomationDirect, Cumming, GA USA. All rights reserved.

SPREAD_AW.indd 2 2104-AutomationWorld_Handbook-Spread-MAG.indd 1

1-800-633-0405

the #1 value in automation

3/28/21 10:19 AM

6LPSOH 3/& FRQWURO

...on STEROIDS! Wi-Fi (antenna sold separately) Bluetooth (provisioning only)

microSD

Stackable I/O Modules USB

Add up to 8 additional I/O modules for applications with larger I/O needs.

Ethernet

Built-in Option Module Slot

n

For custom stand-alone PLC I/O configurations that exactly match your application (option module sold separately).

Serial (RS-232 & RS-485)

s w

y

y e

n

&38 XQLW VWDUWLQJ DW RQO\

$89

We’ve taken our most practical, most popular PLC family and supercharged it with features you wouldn’t expect from a simple low-cost controller. Data logging, Wi-Fi connectability, MQTT communication and increased security measures are just a few of the impressive features offered with the new CLICK PLUS PLC series. With a starting at price of only $89.00 and free easy-peasy programming software, CLICK PLUS PLCs are a “must have” for simple, affordable control...with a kick!

Check out what puts the “PLUS” in CLICK PLUS in this quick intro video: www.go2adc.com/CPVID

www.CLICKPLCs.com

Order Today, Ships Fast! * See our Web site for details and restrictions. © Copyright 2020 AutomationDirect, Cumming, GA USA. All rights reserved.

SPREAD_AW.indd 3

1-800-633-0405

the #1 value in automation

3/28/21 10:19 AM 3/15/2021 12:57:10 PM

2

Product Selection and Applied Technology Handbook 2021

PRODUCT SELECTION & APPLIED TECHNOLOGY HANDBOOK 2021

Contents 06 Assessing HMI Hardware Options 08 How to Select HMI Software 10 Which SCADA System is Right for You? 12 Ensuring a Successful Automation Migration Project 14 Single Pair Ethernet Explained 16 Want Better Performing Equipment to Stay Ahead of the Competition?

19 How Automation Advances Affect OEE

AW2104_Handbook.indd 2

3/26/21 3:55 PM

Full Page Ad.indd 73 210218_FIH-Auto_AutoW_US.indd 1

3/26/21 2/15/21 3:39 12:34PM PM

4

Product Selection and Applied Technology Handbook 2021

Contributors Travis Cox

Karl A. Meier

Jim Coey

Horst Messerer

Linda Htay

Sam Russem

David Kelley

Johann Tang

Inductive Automation

Advantech IIoT Group

IDEC

Panacea Technologies

TruTech Specialty Motors

Helukabel

Grantek

Oriental Motors

Digitalizing hazardous areas.

Enabling connectivity.

Enhancing mobility.

Smartphone for Connectivity in Hazardous Areas

Rugged, intrinsically safe smartphone for Zone 1/21, 2/22, and Div. 1/2 areas Five-inch display and ergonomic design enhance user experience and add flexibility Connects to networks worldwide—supports 21 LTE bands, unlocked for global use Google-certified and Android Enterprise Recommended

www.pepperl-fuchs.com/smart-ex-02

AW2104_Handbook.indd 4

3/28/21 10:26 AM

Full Page Ad.indd 73

3/30/21 8:43 AM

6

Product Selection and Applied Technology Handbook 2021

Assessing HMI Hardware Options

Assessing HMI Hardware Options The importance of HMIs has grown with the increased connectivity of devices and systems in modern manufacturing. To stay relevant to manufacturer’s needs as industry digitizes further, OEMs have to consider multiple HMI options—from built-in and stand-alone displays to color vs. grayscale and processing speeds.

T

he technology in modern human machine interface (HMI) display, controller, and communication hardware provides state-of-the-art multimedia functions. Manufacturers today need these displays to be capable of displaying graphics from multiple sources, such as PLCs, memory sticks, and video cameras.

While most HMI technology revolves around the software, the hardware and design features of the HMI are equally critical to ensure a robust and reliable interface.

PC-based HMIs are known for using what is referred to as an operator interface. The main difference between these operator interfaces and standard HMI panels is the flexibility of the software for PC-based HMIs. This software can be custom written for a particular application or be used to provide a base level of programming. As a result, PCbased HMIs can offer better selection for your software to display your graphics. PC-based HMIs also tend to be physically bigger, allowing them to host a wider range of components and a wider motherboard.

They also require a UPS backup to minimize failures after power loss.

A particular advantage of PC-based HMIs is that they allow for the use of C code and .Net blocks, along with the basic HMI/visualization functionality. This makes it possible to provide high-powered decisionmaking at the point of machine control.

Whichever option you choose, traditional HMI or PC-based, it should be designed from the ground up for industrial applications, instead of being a modification of a commercial design. While commercial products will be cheaper than their industrial counterparts, they won’t last in industrial applications, and may not even function correctly.

SIZE AND COLOR The first thing to assess about an HMI for an OEM should be its display size. Choices typically range from 4.3 to 15 inches. The bigger the display, the easier it will be to view from a distance, but also the more expensive it will be. Another consideration is the amount of information to be shown on the display. If it will be extensive, this could require a larger display, even if the typical viewing distance will be very close.

The next requirement is color or monochrome. Monochrome displays are less expensive, but color provides more options when designing screens. Most suppliers only make monochrome available with smaller display sizes, so the only applications favoring these small monochrome displays will be those with limited amounts of information to be displayed on each screen.

AW2104_Handbook.indd 6

MEMORY AND PROCESSOR PERFORMANCE Like most computer and controller applications, faster CPUs and more memory are desirable. With a faster CPU—millions of instructions per second—quicker operation and response times are realized. An example is instant response to a button press on an HMI, which is highly desirable. Another good indicator of a fast system is one that will start up within a few seconds, compared to others that can take 15 to 40 seconds to boot up. Projects developed for these fast HMIs will download faster and the screens will update faster as well.

In addition to faster scan times, more user memory is also desirable.

More screens, more graphics, more data, and more programming are available with larger memory. A good target for internal user memory is 50 MB or more with additional memory needs covered by use of an SD memory card or similar.

Many suppliers recommend using an integrated system where the HMI runtime is prepackaged with the hardware. This permits the OEM to be confident the HMI has been tested and will run seamlessly with other hardware systems that provide for connectivity.

CONNECTIVITY Hardware connectivity, such as for remote access and monitoring, are becoming as necessary for manufacturers as the device’s control capabilities. These connections in HMIs include Ethernet, USB, and SD memory-card ports. These ports often enable support for multiple industrial protocols simultaneously, as well as FTP server and email functions.

Also be aware that HMIs often need to communicate with other HMIs, PC-based HMIs, other computing platforms, and via the internet. Most HMIs will also need to communicate via USB to PCs and other platforms.

Given these considerations, an HMI should have, at a minimum, at least the following ports: • One serial RS-232/422/485; • One Ethernet; • One A-type and one mini-b USB; and an • SD memory card.

Some suppliers also recommend that HMI hardware should have Power over Ethernet connectivity.

3/26/21 3:11 PM

Improve your bottom line with our top-line performers Need a star performer that won’t send your production over budget? Festo’s Stars of Automation offers a vast inventory of over 4,000 affordable core products ready for delivery. It’s a simpler shopping process, resulting in fewer P.O.s, fewer suppliers and a faster time to market.

Fast Shipping Guaranteed!

24 hours

5 days or less

For great value, look to the stars. Choose Festo.

Discover all the Stars that will brighten your automation process at www.festo.us/stars

Full Page Ad.indd 73

3/26/21 3:40 PM

8

Product Selection and Applied Technology Handbook 2021

How to Select HMI Software

How to Select HMI Software In addition to assessing developer tools and changing user requirements, OEMs must also now take into account remote access concerns when deciding which HMI software to use.

M

arc Andreeson, co-founder of Netscape and the venture capital firm Andreesen-Horowitz, once talked about “software eating the world.” He was referring to the criticality of software to modern businesses and software’s role in overturning established industry structures. And it’s just as true for HMI software.

That’s why the decision-making process surrounding HMI software options is so critical. And the first step in this process is making sure the HMI software you want to use can work with the type of display panel used on the machine.

Historically, HMIs have been all-in-one units consisting of hardware and software. As a result, OEMs are always looking for ways to make them more cost-effective. The tradeoff is a functional limitation in the software to achieve a balance economically. That’s why more OEMs are now looking towards a decoupled approach, where they can get a relatively inexpensive panel PC or touchscreen computer and pair it with the latest and greatest software.

More importantly, software that has management services built in allows a user to centrally manage HMIs by checking health and diagnostics, synchronizing projects, and performing periodic remote upgrades. In this scenario, if the HMI fails, a user can install a new panel PC of any brand, install the same software, remotely send down the application, and be up and running in no time. It is a much simpler approach and much more economical.

In some cases, it may not be easy for OEMs to ascertain beforehand the number of required displays and the complexity of each. This issue can be addressed by selecting a supplier with one HMI programming software package that works with their entire family of displays.

Also, instead of buying the HMI hardware up front, and possibly choosing the wrong model, it may better to select the programming software you prefer first and create the displays as needed.

OEMs can work with a local distributor and download the displays to different target HMIs to make the best selection.

DEVELOPER TOOLS The development environment should be included with an HMI. It shouldn't be separate, meaning that a user would need to download the development environment separately and potentially li-

AW2104_Handbook.indd 8

cense it separately to be able to connect to the HMI and configure it. OEMs should also provide a way for users to connect the HMI to a central management system. That way, rather than having several hundred isolated HMIs, the user can centrally manage them.

Another option is to set up the HMIs to operate independently if the network goes down so that operations can still continue. However, having a centralized management system can help with scalability and maintenance. Having the ability to connect to a centralized management type system to make area-wide changes is powerful.

The information technology (IT) side of an HMI system, including mobile apps, email, and access to files in the cloud or on a network, are all common tools used every day in modern Internet of Things systems. An HMI must have these features to ensure data and information is available locally and in a cloud-based platform.

Mobile apps for Android and iOS devices provide two-way access to HMIs via Wi-Fi, allowing users to monitor PLC parameters or change set points or other variables. These apps provide dialog interfaces to monitor or control most data variables.

These apps should also include features to limit the parameters monitored and controlled. Some of these apps can also upload and download programming software or even delete data from internal memory or external memory devices such as a micro SD card.

Because of the increasing need for this type of connected access, cybersecurity practices, such as limiting users and including a robust username and password, must be followed.

Good mobile HMI apps can include more than data logs, pictures, and similar files. HMI screen shots, alarm log files, and recipe files can also be uploaded and downloaded. In some systems, if an HMI is connected to a PLC, the HMI can download an updated PLC program, eliminating the need to use programming software to complete the task.

CHANGING USER REQUIREMENTS While the IT side of the system is critical to getting data and information to the right places and people, the operational technology (OT) side plays an important role in controlling the machine or process. Because HMIs communicate with controllers, HMIs are often the first devices to touch the data that comes from a sensor, a digital

3/26/21 3:20 PM

Product Selection and Applied Technology Handbook 2021

input, or an internal variable in a PLC. An HMI communicating to multiple industrial protocols simultaneously is a requirement in many automated systems.

Often, multiple controllers from multiple manufacturers are used on a single system.

There are more than 100 PLC protocols, and support for all of them sets an HMI apart from its competition.

With this in mind, the HMI should be selected to meet all communication requirements. Serial and network drivers to communicate with different manufacturers of PLCs will save time and money.

While using an HMI as a communication gateway may not offer real-time control data update speeds, it can still pass data between devices that can be used to make control decisions. HMIs can also act as a data concentrator when communicating with multiple controllers and then feeding that data and information to the IT side of the system.

REMOTE ACCESS CONCERNS Older HMIs simply provided status control— no history and no alarming. Today, more users want to integrate that data natively within the rest of their systems, and technology based on open standards can make that happen. Users want to be able to have local HMI functionality, but also want to connect directly to the rest of their plant and access the data remotely.

This is driving more OEMs to look at incorporating MQTT. With MQTT, a user can plug in a panel device, get local data locally on that panel, but also have that data published automatically into the corporate infrastructure. This allows users to do whatever they want with that data.

One simple and cost-effective way to do it is using HMIs with a built-in web server.

The web server provides this remote access functionality without the need for additional software or hardware.

The web server in the HMI is accessed using any device with a web browser. Accessing the HMI using this method gives a user the same functionality as if they were stand-

9

ing in front of the HMI on the factory floor.

Troubleshooting and maintenance of a system is possible any time and from anywhere, without the time and expenses of travel.

Options in these remotely accessible HMIs include a remote control page, remote monitor page, and a system information page. Simple configuration tools allow a programmer to select the functions that appear on these pages. However, limiting control and monitoring functions available to a remote user should be considered to ensure proper cybersecurity of critical applications.

Typical network configuration of HMIs with web servers includes a local network with Ethernet communication and suitable industrial protocol. The HMI connects to controllers and to local and remote web browser terminals. Proper cybersecurity practices should be followed when using the web browser terminals on external networks to access the HMI on the local network through the local network's gateway/router and firewall.

The ultimate value of remote access for the user will be based on the balance between remote connectivity and security.

When remote access is granted to an industrial system, there needs to be justification for it and there should be buy-in from the IT department. Organizations need to be transparent about what's going on and how systems are connected. There is a high demand for using encryption and the latest security models. OEMs have to demonstrate that security is a big focus they take seriously. Customers want to know that they have encryption, that they have isolation, and that an application uses multi-factor authentication to verify a person’s identity before access is granted.

When data leaves the customer's premises, an OEM has to be able to ensure that there is security. Customers do not necessarily understand what that looks like, so OEMs need to provide tools that a customer can use internally.

ABSOLUTE ENCODERS WITH IO-LINK

Smart Encoder Ready for Industry 4.0

Simplify Your Communications System Magnetic Multiturn Sensing Without Gears or Batteries Perfect for Factory and Process Automation Applications Condition Monitoring via Vibration and Temperature Sensor

The Versatility Champs

www.posital.com

AW2104_Handbook.indd 9

3/28/21 9:58 AM

10

Product Selection and Applied Technology Handbook 2021

Which SCADA System is Right for You?

Which SCADA System is Right for You? Just like all other industrial technologies, supervisory control and data acquisition systems are changing too, and end users should be aware of the new capabilities to make the best decision possible for their operations.

S

upervisory control and data acquisition (SCADA) software has long been a bedrock component of control systems across the discrete and process manufacturing industries.

But as a new generation of automation technologies arises amid the digital transformation of global industry, the way in which industrial operations assess their SCADA needs has changed.

These are the biggest changes to SCADA you should take note of as you make any system upgrade decisions.

SCADA AND THE DIGITAL TRANSFORMATION Plant floor technologies are undergoing a real shift from being part of isolated, air-gapped systems in a siloed environment to being connected to everything else, everywhere. When you are connected to everything, you have to support IT standard-based systems and technologies that allow operations technologies to work with other data-driven systems.

Modern SCADA vendors must be able to provide a superior SCADA system that does not connect directly to devices but is capable of getting data from those devices and providing the context surrounding it. That’s why more SCADA vendors are using open standards, such as OPC UA. Some vendors are also now adopting MQTT, which allows users to plug into a corporate data infrastructure with any application and quickly get the information they need.

And, as you assess SCADA systems, remember that mobility is changing the face of manufacturing technology. Therefore, any SCADA system you’re considering should be able to leverage technologies such as native HTML5 to take advantage of mobile devices.

A big part of your decision-making process should involve assessing SCADA from a security standpoint. SCADA vendors must do all the right things to make sure that OT (operations technology) and IT departments can easily work together. That’s why security must be paramount and any system you’re considering should incorporate the latest tried-and-true standards and security practices, such as HTTPS or SSL for encryption over the web, federated identity providers to identify users, and technologies such as two-factor authentication or single sign-on.

It is critical for manufacturers of all sizes to lock their systems

AW2104_Handbook.indd 10

down properly and have encrypted connections everywhere.

IMPORTANT FEATURES Mobility, Wi-Fi, and HTML5 are advances that some users are not yet taking advantage of in today’s SCADA systems as they should.

For mobility to be most effective, companies should have Wi-Fi enabled in their plants and establish a policy to allow it. There are huge benefits to get data to anyone no matter where they are. Being able to leverage mobile devices by using their sensors, such as GPS or the camera, or to be able to scan a barcode to get more relevant information about what you're looking at can provide incredible benefits.

Another big SCADA advance to be aware of is integration with cloud environments, such as AWS or Microsoft Azure. There are many ways companies can use SCADA in a cloud environment to help OT and IT departments adopt and deploy machine learning algorithms to dramatically improve production.

Edge computing and MQTT are two other new developments for SCADA that aren’t yet being deployed as much as they should be. Some users look at edge computing as an expensive option with an unclear return. But as the cost of edge computing comes down, it is becoming more expensive to replace current infrastructure than it is to add edge computing into the mix. Edge devices are able to process data closer to the source, poll it faster, provide access to more data, and publish it up to a central system or to the cloud. Edge devices also provide features such as store-andforward to ensure data is not lost when connections are down. Users can also potentially embed a computer to talk directly to a PLC, run AWS Greengrass or Azure IoT, incorporate machine learning, and be able to have models running locally to look for things like the machine failure or similar types of applications.

Many companies are so used to the way they do things that they don't want to touch their SCADA system. Companies may look at their system and think: 'If it isn't broke, why fix it?’ Instead, companies need to ask themselves if they want to be stuck in yesterday or look forward to tomorrow. Because this evolution does not require current systems to be ripped and replaced, companies can slowly migrate to address ROI.

3/26/21 3:12 PM

Which SCADA System is Right for You?

SCADA OR DCS? If you’re trying to determine whether to use SCADA or a distributed control system (DCS), the first thing to consider is what a DCS is and what it was built to accomplish.

DCS systems were developed to be end-to-end systems—usually built by a single vendor. The hardware and software are included and designed to work well together. The goal was to make a DCS a simple, straightforward solution.

With that said, distributed control systems have become monolithic. Even though the word “distributed” is in the name, if you had to replace a section or a device, you would have to replace the whole thing. You couldn’t upgrade or replace sections of it. That is why standards groups and organizations, such as the Open Process Automation Forum, were started—to develop open processes and standards so that users were not locked into one proprietary system.

These proprietary systems tend to be coupled directly to devices and other systems, which can be problematic for systems that are spread out or remote. Open protocols, such as OPC UA and MQTT, allow for decoupled architectures where data is published into an infrastructure so that any application can have access to it, thereby promoting scalability and flexibility.

Product Selection and Applied Technology Handbook 2021

11

Essentially, it comes down to making sure that the system you choose is based on open standards and offers unlimited licensing models to allow users to easily scale and expand industrial systems with reduced limitations. When reviewing such systems, be sure they are truly interoperable and offer tools to implement comprehensive security.

LICENSING SCADA systems that can scale are critical, but the biggest thing to consider when it comes to data is the licensing model. The amount of data generated and analyzed will continue to increase. The last thing you want to worry about is how much an increase in data is going to cost. You don’t want to have to ask: How much is it going to cost me to bring in ten more data points or get this data to ten more people?

Many SCADA systems still have these proprietary, legacy-type licensing models—meaning they are not scalable or support open standards. Such systems will not allow you to easily buy a new remote I/O device or sensor and bring it into the system that speaks MQTT natively.

Users need to make a conscious decision to support the technologies using these new open standards created by people in the industry so that they have the right models in place and be able to scale in size and functionality as needed.

Fabco-Made NFPA

Versatile, rugged cylinders—when you need them

FABCO-AIR A member of Festo Group

Our NFPA interchangeable pneumatic cylinders take the guesswork out of cylinder selection.

We design and manufacture our NFPA cylinders in Gainesville, Florida—so expect fast delivery, supply chain resilience and local support no matter your application.

Built tough, our NFPA actuators feature anodized aluminum heads and barrels and stainless steel hardware for corrosion resistance.

They also incorporate high-strength composite rod bears and PTFE piston wear bands for superior load handling and long service life. Choose IURP VWDQGDUG PRXQWLQJ RSWLRQV DQG KXQGUHGV RI VWDQGDUG FRQą JXUDEOH RSWLRQV WR PHHW WKH UHTXLUHPHQWV RI DOPRVW DQ\ DSSOLFDWLRQ Standard catalog not enough? Tell us about your application and let us design a custom solution optimized for your environment.

• Standard bore sizes: 1.5–6 inches • Standard strokes to 99 inches • Pressure rating: 250 PSI

AW2104_Handbook.indd 11

• Temperature range: -10° to +165°F • &RQIRUPV WR 1)3$ GLPHQVLRQDO VSHFLą FDWLRQV • /HDG WLPH IRU VWDQGDUG FRQą JXUDWLRQV r GD\V

MADE IN GAINESVILLE FLORIDA www.fabco-air.com

3/28/21 10:00 AM

12

Product Selection and Applied Technology Handbook 2021

Ensuring a Successful Automation Migration Project

Ensuring a Successful Automation Migration Project Migrating or upgrading a system can be long and often difficult process, which often times leaves organizations secondguessing the project as a whole. However, there are steps you can take to make sure everything is easier and successful.

I

n today’s world, technology is advancing at a breakneck speed, and automation control systems are no exception.

Each year technology may not jump by leaps and bounds like in other industries, but there have been significant advances that allow more efficient control systems, on demand data analytic tools, and a better overall user interface experience.

However, in manufacturing environments it is a costly endeavor to upgrade to the latest equipment. It is certainly not economical to upgrade each year. To most people, it can even feel like an unnecessary exercise to upgrade at all. Operators could have been running the operation on the legacy equipment for years without any major issue. Process and automation engineers have the ability to update the system whenever maintenance is required. So why change anything?

The most important reasons to upgrade aging automation systems are end of life cycle support and security vulnerabilities. Systems that have reached the end of life are usually no longer supported by the OEM. This means that most security flaws are found postmortem and they will most likely not be patched. This also means that replacement parts are going to become scarce. I have seen companies rush to migrate their aging automation system because they only had a handful of replacement parts left.

While it was not impossible to find a new part, the parts they could find were either refurbished on the grey market, or extremely expensive. In regulated industries—such as pharmaceutical and biotech—it is even more important to upgrade to stay compliant with data integrity standards instituted by regulatory agencies like the FDA. Older automation systems were not designed with those standards in mind, so they typically do not have the capability to adhere to them.

If you, or your company, has decided to migrate your existing system, following is an outline of key areas you need to pay

AW2104_Handbook.indd 12

attention to for a successful migration: • It is very important to remember when approaching a migration project that it will never be a one-to-one migration. Even if the automation software or hardware is in the same process family, there have been improvements that have removed or changed past functionality. If you are moving to an entirely new process suite, expect many differences. If you try to keep everything exactly the same, the project will almost certainly go over budget and take more time than expected. Painstakingly recreating humanmachine interfaces, reports or code that were created 10, 15, or more years ago can be potentially disastrous. You would be holding back the new technology that you are upgrading to and you will not see all the benefits of migrating to a new system. Adapting to change and anticipating it will save a lot of headaches during the project and system lifetime. Keeping this in mind also allows you to take full advantage of the new technology.

• When change becomes anticipated you can open up many opportunities for process improvement. At the beginning of your project, perform a system audit or have an experienced integrator evaluate your system. Use this time to discover any changes not previously documented. Check to see if the existing code could be optimized. During this pre-planning period, interview the daily users of the system to get ideas on how the equipment can better meet the business needs of your company. Not all of the suggestions need to be used, but more often than not there will be great ideas that will increase productivity or efficiency.

An added benefit of interviewing your end users ahead of time is that they are more likely to accept or be comfortable with the changes you are planning on making. In the past, I have seen companies ignore their employee’s re-

3/26/21 3:12 PM

13

In regulated industries— such as pharmaceutical and biotech—it is even more important to upgrade to stay compliant with data integrity standards instituted by regulatory agencies like the FDA. Older automation systems were not designed with those standards in mind, so they typically do not have the capability to adhere to them.

quests and they, in turn, heavily resist the changes being made. Once these findings are collected, an informed decision can be made on what needs to change, what can stay the same, and how can you maximize gains from the migration.

• Accept that not all process improvements need to be made at the beginning of a migration project. It is easy to get carried away thinking about what could make your system better, especially with new technology. Settle on specific areas of improvement for the initial migration and determine what changes you have time for in your schedule. If there are any improvements that can’t be done in the time you have or are not critical to the system, set up a future project to add all remaining changes. Unless it is totally necessary, try not to deviate from your original scope once it is set because last minute, rushed changes leave room for oversight and mistakes.

These key guidelines are essential tools that can be used in planning or executing a migration project. They can reduce the stress and headache that come with upgrading aging automation equipment. They will not guarantee a smooth migration project, but they will definitely put you and your company on the right path for success.

Data needs to be sent in the right direction

With the automation market growing, and with it the networking of production structures, the challenge to transmit even higher quantities of data faster is becoming more relevant. The challenges are just as diverse as the solutions provided by HELUKABEL USA.

HELUKABEL USA | West Dundee, IL | helukabel.com

AW2104_Handbook.indd 13

3/28/21 10:01 AM

14

Product Selection and Applied Technology Handbook 2021

Single Pair Ethernet Explained

Single Pair Ethernet Explained This article describes Single Pair Ethernet (SPE) and its applications in industry to help users better understand this emerging Ethernet technology.

T

he first data cables were PVC-insulated single conductors that were stranded into pairs to prevent possible faults.

Later, it was ascertained that low-capacity insulation (e.g., polyethylene) has improved electrical properties, enables longer ranges, and can reduce the use of ferrites (magnets that contribute to fault-free data transmission) during cable assembly. This was common practice in analog technology; and to control each function and each device of a system, a separate pair was required.

This changed with the advent of digital technology. Impedance, cable attenuation, near-end crosstalk, and other properties were defined as cable parameters, and bus technology found its way into automation, system, and mechanical engineering. Suddenly, many devices on a network could be controlled with one cable pair, e.g., Profibus. This succeeded thanks to digital technology and addressing each individual device. The data transmission of bus cables, however, was still very slow in comparison to today‘s possibilities, and achieved a maximum of 20 Mbit.

Ethernet, a uniform data network for networks (LAN technology), was originally used exclusively for office communication. It was not until the turn of the millennium that industrial equipment, connectors, and Ethernet cables were made suitable for industrial use. The industrial Ethernet was born.

In 2015, the automotive industry started to rely more heavily on Single Pair Ethernet (SPE). The advantages are that it is spacesaving, high-performance, and light. It is, therefore, ideal for the enormously increased data rates caused by cruise control, autonomous driving, or the camera system in the vehicle. In the car, an unshielded cable is usually used for 100Base-T1, as the application lengths are <50 ft (15 m).

To make SPE suitable for industrial use, and to help shape the technological changes, the SPE Industrial Network (single-pairethernet.com) was created.

WILL SPE REPLACE INDUSTRIAL ETHERNET? No. The classic two- and four-pair cables have advantages when it comes to range, reaching up to 328 ft (100 m) without a repeater. A further aspect is that four-pair cabling still guarantees a residual transmission of 100 Mbit in the case of failures, or when a pair is mechanically overloaded. With SPE, the analog sensor sys-

AW2104_Handbook.indd 14

This illustration depicts how Single Pair Ethernet allows the extension of Ethernet communications to field level devices such as sensors and transmitters. tem could be digitalized and the comparatively slow bus technology gradually replaced. Furthermore, SPE offers additional advantages compared to the classic industrial Ethernet, especially when it comes to small systems. These include thinner bending radii, smaller cables, and transmission rates of up to 1 Gbit on a single pair. Space advantages like these are decisive for small cameras, in particular, or for collaborative robots that work alongside humans.

OW DOE ONE PAIR DATA TRANSMISSION ACTUALLY FUNCTION? Classic Ethernet works with a four-pair Cat 5 cable within a frequency range of up 100 MHz. The individual pairs send/receive interchangeably, and up to 1 Gbit can be transmitted. In the case of SPE, only one pair is available. In order to be able to transmit 1 Gbit, chip sets with a range of up to 600 MHz are used. Some frequencies in the wide spectrum receive, while other frequencies send...

This is how SPE works.

WHY IS SPE OF INTEREST FOR INDUSTRIAL USE? SPE enables consistent data transmission to the field level. This means that only one pair is required to transmit the signals instead of the previous two or four pairs.

In this way, SPE matches the industrial requirement profile exactly, and offers the following advantages (compared to the classical industrial Ethernet):

3/29/21 1:28 PM

Single Pair Ethernet Explained

• Thinner cables; • Lower cost of assembly; • Less space requirements, lower weight, smaller laying system possible, if necessary; • Smaller bending radii and smaller drag chains in the case of continuously moving applications; • Lower caloric load, less smoke development; and • Less materials like copper or plastic protects resources.

Furthermore, current digital bus technology and analog sensor technology is used at the lowest level. SPE lays the foundation for the digitalization of sensor technology, so that Ethernet can be used right up to the sensor.

APPLICATION AREAS SPE covers the requirements of diverse industries. This means that cables are used depending on the application, e.g., for fixed installation, for flexible use, or for highly dynamic applications, such as in drag chains or in robots. Jacket materials can be PVC, FRNC, or PUR, depending on customer needs and application. High-temperature materials, such as fluorinated ethylene propylene, may also be implemented.

For factory automation, in addition to the options for expanding or substituting SPE in classic sensor and industrial Ethernet cables, there will also be future possibilities with CAN bus working with SPE 1000Base-T1 up to the 130 ft (40 m) range. As well as saving

Product Selection and Applied Technology Handbook 2021

15

on weight, this will enormously increase data speed.

For process automation, with 10Base-T1L, SPE also offers a quantum leap in process automation, where for decades data rate transmissions have been 31.25 kBit. For example, SPE10Base-T1L 10 Mbit enables video transmissions from security cameras up to max. 3280 ft (1000 m) (not possible with Profibus PA).

POWER OVER DATA LINE (PODL) Thanks to PoDL, SPE also makes power supply possible parallel with data transmission. The classifications shown in the image below provide an overview for end devices up to maximum 50 Watts power transmission.

HYBRID CABLES FOR LARGER POWER REQUIREMENTS If the PoDL classifications up to a maximum of 50 Watts do not cover the power requirements of the device, SPE hybrid cables and M8 connectors provide the ideal solution with more power.

In this case, the cable contains an Ethernet pair with AWG 22-24 and two AWG 18 power conductors that provide up to 400 Watts at 60V over a distance of 130 ft (40 m). It is mandatory to shield the data element pair. It is also possible to have an overall shield as well.

This image highlights how Single Pair Ethernet technology fits within industry standards, components, and devices, as well as the varied applications into which it can extend.

AW2104_Handbook.indd 15

3/26/21 3:13 PM

16

Product Selection and Applied Technology Handbook 2021

Want Better Performing Equipment to Stay Ahead of the Competition?

Want Better Performing Equipment to Stay Ahead of the Competition?

Learn how easy it is to optimize servo motors to increase your machine’s performance.

T

his brief introductory focuses on those OEMs looking to increase machine performance and already utilize or intend to incorporate motion control as the main forces for axes in motion.

It is commonly accepted that today’s machinery depends on performance deliveries that outpace previous methods. However, designers and engineers of tomorrow’s machines continue to be challenged and search for new solutions that meet requirements with greater reliability demands, higher quality standards, and increased production outputs. Providing results is expected regardless of existing equipment with projected upgrades or completely new machine designs. Along with the right choice of motion system for controls and drives, servo motors are the key elements that help provide unsurpassed machine performance.

Most machinery and equipment today have competitive equivalents, and each have their following. Many other machines exist that have no equal, and these continue to carve out niches in their respective fields. Servo motors installed on all types of equipment are main components of these machines. Irrespective of the application or industry that equipment is intended for, the machines themselves are purposely designed to produce certain products or process methodologies. Why shouldn’t servo motors follow suit? Controllers and drives traditionally enjoy enclosure comfort, whereas servo motors are directly embedded into the machine itself. Plain and simple, designing the machine around the motor may not provide for best results. Whereas, designing the motor around the machine most certainly does!

Choices for, and implementation of, servo motors have a vast range of possibilities. Market available models come as standard for many suppliers and the applications where they are applied can vary as well. Catalog solutions from suppliers can already fulfill a multitude of needed motion requirements and these are widely acceptable. Where slight motor changes may be preferred, some modifications can generally be accommodated, but many suppliers may request that machine designers alter the machine to fit the motor instead. Where more significant changes to the motor are requested, but standard elements still need to be implemented and applied where

AW2104_Handbook.indd 16

possible, more in-depth considerations may be undertaken; but many suppliers simply cannot provide a solution, thus leaving the machine builder to consider yet more machine alterations.

Worse yet, when it appears as if the design of the motor is so unique that limited choices, if any, escape machine designers and/or engineers attempting to meet the new requirements, a machine redesign may be necessary. Going the route of a custom motor design is deemed too complicated, assumed to take too long for delivery of prototypes, or becomes too expensive.

Well, not anymore!

Partnering with the right servo motor solutions provider can be an extension of the OEM’s design and engineering teams.

Working alongside the OEM’s preferred motion control systems manufacturers of controls, drives, feedback etc., machine builders can not only have designs tailored and delivered to exacting needs, but also help the OEM be more than cost competitive overall. In fact, provided motor solutions have resulted in deliverables that exceeded initial projections. In many cases, some mechanical parts can be removed from the machine given the final motor conceived and designed. Some motors can become completely integrated into the machine with various sub-assemblies.

Low voltage, IP67, BLDC motor specifically designed for submersible use.

3/29/21 1:27 PM

Full Page Ad.indd 73

3/29/21 11:19 AM

18

Product Selection and Applied Technology Handbook 2021

Better still, and when taking a larger systems approach, many elements providing motion for an axis can be incorporated into a single unit and delivered as a more complete motor system assembly. Just think about it, if one can consider a reduction of machine complexity, it is no longer just a motor conversation but a realization of how to help make the machine exceed expectations or expand to new possibilities!

Armed with new, and more complete information available from TruTech Specialty Motors’ white paper, “Optimizing Servo Motors for Increased Machine Performance,” (awgo.to/dqjgo) machine designers and mechanical engineers can provide their companies with the solutions they seek. Opting for servo motor manufacturers that partner with the OEM to provide overall solutions dedicated to helping maximize a machine’s operation will deliver excellent results. With optimized servo motors that are pure form, fit, and function, a new era in machine performance can be fulfilled.

Want Better Performing Equipment to Stay Ahead of the Competition?

IP67, 300mm (O.D.) hollow shaft, high voltage and torque, outer rotational BLDC motor used in food processing.

IP67, 330mm (O.D.) BLDC motor used in submersible water pumps optimized for delivering high torque at low speeds.

IP 68 seamless enclosure, stainless-steel housing BLDC servo motor with watertight cable entry glands and customer-specified pitched screw shaft adapter for harsh environment compliance.

There are many ways to detect an object...

By light...by sound... ...by physical contact...

The real challenge is determining the best method; and then becoming an expert in that discipline. For over 95 years, Telemecanique Sensors has been a world leader in detection technology, making the choice of of a sensor “partner” obvious.

Need to see, hear, feel, or sense an object’s presence?

Browse a comprehensive selection of photoelectric sensors, ultrasonic sensors, limit switches, inductive sensors, pressure sensors and more at www.tesensors.com

AW2104_Handbook.indd 18

Simply easy!

3/29/21 1:29 PM

How Automation Advances Affect OEE

Product Selection and Applied Technology Handbook 2021

19

How Automation Advances Affect OEE Overall Equipment Effectiveness is a long-used equation to determine the effectiveness of production machines. But as automation technologies—and their associated analytic capabilities— rapidly advance, what role does OEE serve as industry digitizes?

F

ew argue about the value of production insights delivered by the well-known OEE calculation. In essence, OEE is a great tool to help understand how well a line is running. This metric can be used to compare similar production systems and determine where improvements can be made most effectively.

If you're wondering whether or not you need to replace or fix equipment on a line or if you can get more productivity out of an existing line through targeted investments, OEE can be very valuable.

AW2104_Handbook.indd 19

But to deliver insights precisely enough to be of real value in determining new investments—especially in light of all the advances that have been made in automation technologies over the past few years—OEE needs context. And to understand how to connect OEE calculations with operational context as industry increasingly digitizes its operations, Automation World connected with Sam Russem of system integration firm Grantek to get a better grasp on this issue for an episode of the “Automation World Gets Your Questions Answered” podcast series.

3/28/21 10:14 AM

20

Product Selection and Applied Technology Handbook 2021

How Automation Advances Affect OEE

OEE AS A TOOL Russem noted that a common mistake he sees manufacturers make when installing software or systems to help determine OEE is that they expect the system alone to drive improvements. “OEE is a tool,” he said. “It's another tool in your toolbox to let you know where you're struggling. But it's not a prescriptive system that tells you necessarily how to fix a specific problem. So for OEE to drive extra value into your business, you need some type of program and the proper funding around it, whether it’s a continuous improvement engineering team focused on identifying and driving those projects for improvement based on OEE data, or the use of more in-depth analysis tools.”

Despite OEE’s inability to deliver prescriptive corrections on its own, Russem said OEE can illuminate a lot of other roadblocks that could hinder a digital transformation program.

“OEE can serve as a checklist to see how ready you are for digital transformation initiatives,” he said.

OEE is capable of doing this because of the core production information it provides. “So much of digital transformation is about collecting data and putting the proper context around it to drive more informed decisions,” Russem said. “And an OEE project is going to require you to collect some standard data from each of your lines and machines, which means that all those machines need to be networked or somehow communication-enabled to send the raw data to a server or system that can put information around it. It doesn’t have to require the use of cloud computing technologies or machine learning, but it does need the framework to collect and transmit the data. In itself, OEE is not that type of modern transformative technology that I personally associate with digital transformation or Industry 4.0, simply because it's a metric that's been around on paper for years and years. But it is valuable within a digital transformation initiative as a benchmark to see if you're ready for other data enablement projects and to determine if your digital system [is robust enough to] prescribe changes or identify the key performance indicators to focus on to measure the effectiveness of digital transformation projects.”

INFRASTRUCTURE, DATA INTEGRITY, AND CONTEXTUALIZATION

Infrastructure is a significant roadblock because of the expense. “If you're not collecting data, because you need to get more machines on the network or upgrade PLCs, you might find that the cost of that infrastructure and hardware is going to be higher than the actual cost of the OEE system,” noted Russem. “To overcome this, manufacturers have to think bigger and consider all of the other value beyond OEE that infrastructure upgrades can bring and how that's going to contribute to the overall digital platform. Any digital transformation project is going to need data, so putting the infrastructure in place to support an OEE program will also support the rest of your digital transformation initiative—and that helps support the financial justifications needed for these upgrades.”

Data integrity is another particularly tough roadblock for many manufacturers, according to Russem. “Maybe your part counters aren't accurate; maybe the downtime code sent to OEE isn't really what stopped the line; maybe the way the system counts rework doesn't align with the way it was formerly calculated on paper. Any of these can cause people to not believe the data going into or coming out of the system, and that can lead to a loss of faith in the systems and hinder buy-in and acceptance of it very quickly,” he said. “For these reasons, it’s critical to include time for data validation and to have a plan in place for what you're going to do if you do find a gap during the validation.”

The third issue Russem noted is data contextualization for use by an ERP system. An OEE calculation should be based on what product is being produced on a given line, Russem said. “This can be really valuable if you're expecting to find different evaluations based on what SKU you're running and you want to investigate those differences. Or maybe you have different ideal performance and throughput rates, depending on the product you're running.

In either case, the system needs to know that to make sure you're benchmarking against the right thing.”

Russem added that this kind of information isn't always available when starting a new OEE project—and that might mean some level of ERP integration is going to be required. “In that case, OEE becomes your first step in enabling the digital transformation by connecting production systems to enterprise systems as well to lower-level automation technologies to exchange data automatically,” he explained.

For OEE to play an effective role in the digital transformation of a manufacturing business, the data collection and transmission systems supporting it must be installed and used correctly. Based on his work with a variety of manufacturers, Russem highlighted three common areas that tend to create problems for manufacturers when they're installing systems from which they can derive OEE. Those roadblocks are: infrastructure, data integrity, and data contextualization for ERP integration.

AW2104_Handbook.indd 20

3/26/21 3:13 PM

Full Page Ad.indd 73

3/26/21 3:45 PM

IP67 RATED

I/O SYSTEM FIELD A MODERN APPROACH TO IP67 RATED DISTRIBUTED I/O • • • •

Fieldbus Communications – PROFINET, EtherNet/IP, EtherCAT, Modbus, IO-Link IIoT Protocols – MQTT, OPC UA, HTTP(S), Bluetooth Integrated Load Management – Monitor power consumption, set alarms, and adjust output current Ready for the Future – Made for TSN

www.wago.us/V\VWHPƮHOG

Page Ad.indd IOFull Field Ad.indd 1 73

3/26/21 PMAM 3/26/213:42 8:39