Automation World November 2020

NOVEMBER 2020 / www.automationworld.com

20 COLLABORATIVE ROBOTICS EXPAND IN SCOPE 26 08 09 32 11 16

New PLCs Gain Esteem as the Brains Behind the Machines Cobots and the Rise of Lean Integrators Industrial AI and the Self-Optimizing Plant Data: It Does a Milk Producer Good Automation and the Supply Chain Intel Targets Digital Transformation with New Processors

2011_Cover.indd 1

10/29/20 10:27 AM

NEW! GS20 DRIVES The GS20X for your messiest environments.

GS20 STARTING AT

$135.00 (GS21-20P2) GS20X STARTING AT

$216.00 (GS21X-20P5)

GS20 nd GS20X G n r Purpos

C Dr

s

Starting at $135.00 (GS21-20P2) The GS20 and GS20X drives take the best features of our popular GS2 series drives, add Sensorless Vector and Field Oriented Control, expanded built-in I/O, and include an integrated PLC with optional Ethernet communications. If that isn’t enough, the GS20X models come with a NEMA 4X enclosure so you can install them in a wash-down location. You’ll have a hard time believing that a drive this feature-rich costs as little as it does!

so Stainless Steel Motors

IP69K Rated Stainless Steel NEMA Photoelectric Sensors 4X Enclosures

• Broad size offering from 1/4 to 30 hp (GS20) • NEMA 4X models available up to 10hp (GS20X) • Input voltages available: 120VAC, 230VAC, 460VAC and 575VAC • Built-in PLC supports up to 2K steps • Built-in USB port for fast & easy programming • 100kA Short Circuit Current Rating • Built-in Dynamic Braking – optional resistors • PID Controller – including sleep and wake • GS2 mode duplicates exact parameter configuration of existing GS2 drives (GS20 only) • Two year replacement warranty • UL/CE listed

Research, price, buy at:

www.automationdirect.com/GS20

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

2011-AutomationWorld-GS20GS20X-MAG.indd 1 Full Page Ad.indd 73

1-800-633-0405

the #1 value in automation

10/16/2020 2:46:21 PM 10/29/20 11:09 AM

What if food packaging were carbon-neutral?

Go nature.

Go carton.

Food packaging plays a critical role in getting food safely to consumers around the world. But it can also cause problems for the planet. What if all food packaging came from plant-based materials and didn’t impact the climate? At Tetra Pak, we already have paper-based carton packages with reduced climate impact. But we won’t stop there. Our aim is to create cartons made solely from plant-based materials that are fully renewable, fully recyclable and carbon-neutral. It’s all part of our journey to deliver the world’s most sustainable food package.

Learn more at gonature.tetrapak.com

Full Page Ad.indd 73 187921_TetraPak_GNGC_Ad_India_Automation_World_9x10,875_US.indd 1

10/29/20 11:09 AM 01/10/2020 14.34

2 CONTENTS

AW NOVEMBER 2020

NOVEMBER 2020 | VOLUME 18 | NUMBER 11

20

Collaborative Robotics Expand in Scope

26

PLCs Gain Esteem as the Brains Behind the Machine

As the development of collaborative robotic systems continues, the line between typical industrial robots and those deemed “cobots� continues to blur.

New controllers are offering multifunctional automation with more intelligence and connectivity, opening the door to new opportunities for machine builders and end users.

It Does a Milk Producer Good 32 Data: Transforming raw materials into a variety of milks and ice cream mixes, Agropur lacked the data needed to improve its operations. An integrated control and information system from Rockwell Automation provided the needed visibility.

2011_TOC.indd 2

10/29/20 11:42 PM

200619_AutoSICK-1_AUTOW_US.indd 1 Full Page Ad.indd 73

6/19/20 9:07 AM 10/29/20 11:10 AM

4 CONTENTS

AW NOVEMBER 2020

EDITORIAL

ONLINE 6

Exclusive content from AutomationWorld.com: videos, podcasts, webinars, and more

INDUSTRY DIRECTIONS 8 Cobots and the Rise of Lean Integrators

BATCH OF IDEAS 9

Industrial AI and the Self-Optimizing Plant

NEW TECHNOLOGY SPOTLIGHT 10 Advances in Controller Connectivity and Performance

PERSPECTIVES 11

David Greenfield Director of Content/Editor-in-Chief dgreenfield@automationworld.com / 678 662 3322 Luis Rodriguez Managing Editor lrodriguez@automationworld.com / 312 205 7910 Stephanie Neil Senior Editor sneil@automationworld.com / 781 378 1652 Aaron Hand Editor at Large ahand@automationworld.com / 312 222 1010 x1180 Jim Chrzan VP/Content and Brand Strategy jchrzan@automationworld.com / 312 222 1010 x1470 Kim Overstreet Content Strategist koverstreet@pmmimediagroup.com James R. Koelsch, David Miller, Lauren Paul, Jeanne Schweder and Beth Stackpole Contributing Writers

ART & PRODUCTION

Automation and the Supply Chain Artificial Intelligence Advances Food Safety Understanding Virtualization for Industrial Automation

Filippo Riello Art Director friello@pmmimediagroup.com / 312 222 1010 x1200 George Shurtleff Ad Services & Production Manager gshurtleff@pmmimediagroup.com / 312 222 1010 x1170

NEWS 16

ADVERTISING

Intel Targets Digital Transformation with New Processors AI-Embedded Operator Interface App Organizations Join Forces to Address Digital Transformation Challenges for Oil and Gas PMMI News

Kurt Belisle Publisher kbelisle@pmmimediagroup.com / 815 549 1034 West Coast Jim Powers Regional Manager jpowers@automationworld.com / 312 925 7793 Midwest, Southwest and East Coast

INDUSTRY-SUPPLIED CONTENT 34

AUDIENCE & DIGITAL

Single Pair Ethernet Explained

David Newcorn Senior Vice President, Digital & Data Elizabeth Kachoris Senior Director, Digital & Data Kelly Greeby Senior Director, Client Success & Media Operations Jen Krepelka Director, Websites & Digital Design Strategy

NEW PRODUCTS 36

Mobile Robot Moves Payloads Up to 250 kg Machine Vision Camera Offers NIR Imaging Advanced Power Quality Meter And more...

PMMI MEDIA GROUP

Kurt Belisle Publisher kbelisle@pmmimediagroup.com / 815 549 1034 Jake Brock Client Success Manager jbrock@pmmimediagroup.com / 312 222 1010 x1320 Sue DaMario Director of Marketing damario@pmmimediagroup.com / 312 222 1010 x1710 Amber Miller Marketing Manager amiller@pmmimediagroup.com / 312 222 1010 x1130 Sarah Loeffler Director, Media Innovation sloeffler@pmmimediagroup.com / 312 205 7925 Janet Fabiano Financial Services Manager jfabiano@pmmimediagroup.com / 312 222 1010 x1330

FINANCE VIEW 41

Practical Advice to Increase Manufacturing Profitability By Larry White

IT VIEW 42

The Connected Plant in the Digital World By Sanjiv Kumar

KEY INSIGHTS 44

All Automation World editorial is copyrighted by PMMI Media Group, Inc. including printed or electronic reproduction.

Magazine and Web site editorial may not be reproduced in any form without the written permission of the publisher.

Automation World | PMMI Media Group 401 N. Michigan Avenue, Suite 300, Chicago, IL 60611 Phone: 312 222 1010 | Fax: 312 222 1310 www.automationworld.com PMMI The Association for Packaging and Processing Technologies 12930 Worldgate Dr., Suite 200, Herndon VA, 20170 Phone: 571 612 3200 • Fax: 703 243 8556 www.pmmi.org

26

2011_TOC.indd 4

10/29/20 10:21 AM

The Plant Floor in Your Pocket Get an overview of your process at a glance.

Control your SCADA with a swipe.

See the live demo now.

Scan this QR code with your phone or visit demo.ia.io/automation

Full Page Ad.indd 73

10/29/20 11:10 AM

6 ONLINE

AW NOVEMBER 2020

PODCAST SERIES Beginning the Digital Transformation Process

In this episode, we connect with Bill Pollock, CEO of Optimation, to explore how industrial companies are moving forward with their digital transformations. We discuss how to assess current operations, avoid common mistakes, and apply metrics.

awgo.to/1108

AUTOMATION WORLD TV Automation World’s YouTube site offers relevant videos on the latest industrial automation insights, trends, and news. Check out our videos and subscribe to keep up with the latest technology and application developments.

awgo.to/1055

AUTOMATION WORLD E-BOOK Automation World’s Field Guide to IIoT Implementation

The Industrial Internet of Things (IIoT) promises increased productivity, better quality products, and more affordable operations. Automation World created “The Field Guide to IIoT Implementation” to answer your questions around IIoT and detail key benefits to integrating IIoT products, steps for applying application program interfaces to implement these products, and factors to consider before launching an IIoT initiative.

awgo.to/1070

THE AUTOMATION PLAYBOOK The Automation Playbook is a useful source of information as you look for guidance in how to approach the Industrial Internet of Things, communication protocols, controls implementation, safety, asset management, predictive maintenance, the mobile workforce, and much more.

awgo.to/1056

SYSTEM INTEGRATOR BLOGS • Accessing the Far Regions of Automation • Technological Transitions During a Pandemic • Simulation Environments: Worth the Investment?

• Reducing Validation and Execution Efforts by Standardizing • The Training Without Application Blues

2011_WebTOC.indd 6

awgo.to/1025

10/29/20 10:21 AM

MORE MEMORY, FASTER PROCESSOR OUR MOST POWERFUL LINE OF CONTROLLERS: PFC200 SERIES • 4 GB onboard Flash, 32 GB SD card • 1 GHz Cortex A8 processor • Program with standard PLC languages: ladder, structured text, function block and more • Built-in HTML5 web server for dynamic operator interface

RS

232 485

IIoT Y D A E R

www.wago.us/pfc200

PFC200 G2 AW.indd73 1 Full Page Ad.indd

9/25/20 11:11 10:35AM AM 10/29/20

8 EDITORIAL

AW NOVEMBER 2020

INDUSTRY DIRECTIONS

Cobots and the Rise of Lean Integrators

By David Greenfield

dgreenfield@automationworld.com Editor-In-Chief/ Director of Content of AutomationWorld

T

he rise of system integration firms to help manufacturing companies design and commission industrial robots and other advanced automation systems over the past several decades has predominantly been a boon to larger manufacturers. The business model of these integrators evolved along with the demands of the larger manufacturing customers they served, as the implementation of these technologies often required changes to a facility’s power structure, floor plan, and operational procedures. The overhead associated with these projects meant that the system integration contract was rarely less than $250,000, thereby putting these projects out of reach of most small to mid-sized enterprises (SMEs).

Joe Campbell, senior manager of applications development, at Universal Robots, notes that the impact of this model has had big effects on the manufacturing industry as a whole. He points out that, in the first decade of the 21st century, large manufacturers were able to grow their productivity with advanced automation technologies by 300%. But smaller manufacturers, with less than 500 employees, were only able to achieve 200% gains in productivity. Of course, a 200% gain in productivity is nothing to be dismissed, but there is a clear gap between the automation benefits available to larger manufacturers through the aid of traditional system integration firms.

2011_E1.indd 8

In response to this gap, Campbell points to the rise of a new type of system integrator— a type of organization he refers to as lean integrators. “The lean integrator evolved precisely to address the SME market’s growing demand for robot installations that yield higher productivity at a lower price point and that can be installed in a fraction of the time of a traditional robot work cell,” says Campbell. “Like the SMEs they serve, lean integrators are small enterprises themselves.

The two features that distinguish lean integrators from their traditional counterparts are size and speed.”

Describing lean integrators in more detail, Campbell notes that these firms typically focus on mastering one or two end applications within a regional market and often employ no more than 10 to 15 people, “Their operational footprints rarely exceed 10,000 square feet, and they tend to deploy capital on knowledge workers rather than equipment for vertical integration. All this translates into much lower operational overhead while spurring innovation, which enables lean integrators to be successful even when taking on projects under $100,000,” he says.

“It also allows them to commission cobot [collaborative robot] installations within weeks rather than the months-long process required to integrate industrial robots.”

One of the lean integrator firms that Campbell references is Vectis Automation, founded in 2019 by a small team of engineers with expertise in traditional robotic welding applications. With the average age of a U.S. welder being 55 and likely to retire within 10 years, this makes the services offered by Vectis Automation particularly attractive to manufacturing operations that rely on welding.

To streamline its lean integrator business model, Vectis Automation has partnered with Universal Robots to create a system-level product. Campbell says, “Vectis can then add

value by tailoring the cobot, equipment, and software to the customer’s application. The Vectis team’s collective background in welding allows them to bring unique expertise to customer application support and develop software targeted to welding fabricators.

They know what makes a good weld, and they’re able to apply that knowledge to the cobot product kit.”

According to Josh Pawley, director of business development and Vectis Automation co-founder, Vectis—with its lean integrator approach—can install cobots for welding applications in hours or days instead of weeks or months.

Another lean integrator is Fusion Cobotics.

This company is not a new system integrator, but one that started in 2002 as a traditional integration firm and transitioned into lean integration in 2018 with the use of cobots to tend the company’s CNC machines.

This led the company to begin focusing on helping small to medium-sized job shops performing high-mix, low-volume applications to automate the tending of CNC mills and lathes, as well as press brakes for sheet metal.

Craig Zoberis, Fusion’s president points out that, “even by lean integrator standards, Fusion’s physical operation is small.

We dedicate 15 by 15 feet of floor space and an engineering staff numbering under 10 people to assemble and test a customer’s system before installing it within weeks of the initial meeting. Such projects require an investment between $60,000 and $150,000, depending on project size, but 80% are under $100,000.”

10/29/20 10:21 AM

EDITORIAL 9

AW NOVEMBER 2020

BATCH OF IDEAS

Industrial AI and the Self-Optimizing Plant

By Stephanie Neil

sneil@automationworld.com Senior Editor of AutomationWorld

I

n manufacturing, the focus is often on decreasing downtime and increasing productivity. But there are other elements that influence operations—including safety, reliability, and environmental impact. It’s clear that technology can help, especially artificial intelligence (AI) and analytics, which can be used to optimize processes and predict disruptions.

But not all AI is created equal. Aspen Technology (AspenTech), a maker of asset optimization software for process industries, recently released a new version of its aspenONE software that embeds industrial-strength AI across the portfolio. This is not your standard AI, company officials said, as it is not only about the algorithms, but also embedding domain expertise to contextualize AI so that it is specific to the industry, thereby creating insights and knowledge that adds value and can even transform the business.

It’s what the company calls Aspen Hybrid Models, which are part of the new aspenONE V12 software release, that applies data science, data cleansing, machine learning, and predictive insight into complicated processes.

“We are taking decades of domain expertise and embedding AI into that,” said Laura Rokohl, senior director of product marketing at AspenTech. “We believe this helps advance our customers’ digitalization journey, but in terms of our vision as company, it’s this journey to the self-optimizing plant where things

2011_E2.indd 9

are moving toward autonomy and a closed loop. It’s a longer-term, multi-year journey but we feel this release helps us take initial steps toward the self-optimizing plant by embedding AI, automating things that were previously manual processes or required human intervention, and lowering the barrier to solve complex problems with less expertise.”

For example, mining plant data collected over years would previously require a controls expert to build the advanced process control (APC) model and it would take a few weeks to complete. With embedded AI, the model-building process is reduced. “It takes historical data, mines it, and creates a seed model. We refer to it as expertise-in-abox. It dramatically reduces the time it takes to build that model as many of the steps are automated and packaged up,” Rokohl said, noting that while it doesn’t eliminate humans from the equation, it also doesn’t require 30 years of APC expertise.

According to Peter Reynolds, a senior analyst at ARC Advisory Group, “AI has the potential to enhance many industrial work processes; however, most companies are not well-equipped to bolt on AI themselves.

While other technology strategies require asset owners to invest in complex platforms and data scientists, with embedded AI users can get started right away improving margins and profitability.”

And that is the first step to the self-optimizing plant.

AspenTech defines the self-optimizing plant as a facility that can automatically respond to changing operation conditions. The company is now rolling out technology that delivers this next generation of production optimization, including planning and scheduling, performance management, and adaptive process control that can continuously improve plant processes related to equipment wear, upgrades, feedstock quality changes, and fluctuating economic models. To that end, the

aspenONE V12 release includes several new functions that can be added to the company’s existing product portfolio, thereby democratizing the application of industrial AI. AspenTech is also going beyond its core industry segments of energy and chemicals and branching out into metals and mining and food and beverage by including in V12 some functionality relevant to those industries, like its MES (manufacturing execution system) Collaborative application. MES Collaborative is an enterprise historian that sits in the cloud and can securely access data from sensors, programmable logic controllers, or an existing historian, for example, to pull more information into the enterprise view.

Ultimately, AspenTech recognizes that the way plants work will have to change in the future, and they are laying the groundwork for that shift.

“The process industries and other capitalintensive industries are experiencing new levels of volatility in supply and demand, and the need to be agile in response to all market conditions requires a new approach to asset optimization,” said Antonio Pietri, president and CEO at AspenTech. “This next generation of industrial AI solutions will change how process industries work.”

“AI has the potential to enhance many industrial work processes; however, most companies are not well-equipped to bolt on AI themselves.”

10/29/20 11:41 PM

10 EDITORIAL

AW NOVEMBER 2020

NEW TECHNOLOGY SPOTLIGHT

Advances in Controller Connectivity and Performance

By Luis Rodriguez

lrodriguez@automationworld.com Managing Editor of AutomationWorld

A

s more Internet of Things and Industry 4.0 initiatives are planned by industrial companies of all sizes, controllers increasingly need to meet the performance, monitoring, connectivity, and security needs required by connected manufacturing processes.

One example of a new controller specifically designed for such tasks is the CP2E series of controllers from Omron Automation Americas. These controllers feature two Ethernet ports with Ethernet switching function for host and human-machine interface connectivity, and up to three serial ports for open connectivity to serial devices.

Another new controller of note is the Modicon M262 from Schneider Electric.

This controller features up to five independent Ethernet networks for use with open protocols such as OPC UA, PackML or SQL as well as secure cloud connectivity via MQTT, JSON, or HTTPS. To handle the potential risks associated with an internet-connected controller, the Modicon M262’s embedded safety complies with regulations up to SIL3 through encrypted communication, network separation, and Achilles certification.

The new B&R X20CP3687X controller features a Time-Sensitive Networkingenabled Ethernet interface for communication using the manufacturer-independent standard OPC UA over TSN.

2011_E3.indd 10

Additional features of these controllers include: • The CP2E series controller can automatically detect and recover from bit corruption to increase machine efficiency and avoid CPU stops; and its I/O terminal LED indicators enable quick root cause identification. Also, the controller’s ability to use function block programming makes it easy to achieve four-axis positioning function with linear interpolation. The controller also provides PID control with auto-tuning function block for stable temperature control.

• With the ability to control from four to 16 synchronized axes, the Modicon M262 controller features a scalable cycle time down to one millisecond and a three nanosecond-to-instant processing speed independent from communication tasks, making it well suited for demanding motion applications.

Schneider Electric says the Modicon M262 can be also used as an “all-in-one” motion controller with its embedded motion bus, encoder, and touch probes.

Modicon M262 from Schneider Electric

X20CP3687X controller from B&R

• B&R says the powerful processing, additional RAM, and integrated onboard flash memory of its X20CP3687X highperformance controller enables it to handle complex control algorithms as well as robotics applications that typically require an industrial PC.

CP2E series of controllers from Omron Automation Americas

10/29/20 2:45 PM

PERSPECTIVES 11 AW NOVEMBER 2020

Automation and the Supply Chain

By David Greenfield,

Director of Content/Editor-in-Chief

S

upply chain and production operations exist in a world where they are inextricably linked yet often function quite separately. And there are few places where this is more evident than in automation technologies. I say this because most discussions of supply chains focus on transportation logistics and tracking of shipments; but how do the supply chain technologies that support these functions affect production operations?

This connection is not so often explored.

To find out more about this, we connected with Matt Ruth, president of Avanceon, for a recent episode of the “Automation World Gets Your Questions Answered” podcast series (http://awgo.to/automationsupply). Avanceon is a system integration and engineering services company focused on industrial automation systems ranging from manufacturing execution systems and analytics to industrial Internet of Things projects, as well as delivery of automation technologies as a service.

Ruth began our conversation by noting that Amazon and Walmart are very publicly tackling the last mile supply chain delivery issues with drones and different kinds of fleets. In turn, warehouse and inventory levels are reduced as things ship more just in time. “So there's a natural progression upstream into the operational piece as a next step in efficiency,” Ruth said. “And we're seeing planning and operations that need to be functioning in a more predictive manner in order to anticipate and meet that just-in-time demand, but without having to create too much inventory of finished goods.”

He explained that this means manufacturers have to better understand what the demand is, what the transportation is going to look like, and to be more precise with their planning. They need to be more “accurate and predictive in the cycle times of the specific items they need to make and understand how changeover mixes in and what the likelihood

2011_Perspectives.indd 11

of downtime and failures are. This means a lot more granularity in [manufacturing] detail needs to be added, as well as more flexibility in batching systems and packaging lines to convert from one SKU to another. We see this happening in minor doses now, but we expect to see this more holistically across the board.”

To address this with automation technologies, Ruth noted that one of the most important things is having bi-directional data flow from the enterprise resources planning (ERP) system to the manufacturing systems.

“Oftentimes a supply chain or ERP system pushes information down to the plant, but it doesn't receive a lot of information back. This allows operations to execute against the ERP but doesn't do a lot to improve the status of the information or understanding of people using the system to really know how things are progressing and make better decisions in real time. There's certainly detailed information that doesn't belong in the ERP, like the pressure of a certain vessel at a certain time, but there’s a lot of missed opportunity by not automating the collection back or not having any or very little production information.”

Explaining how this can or should affect decisions around production automation technologies, such as controllers, human-machine interfaces, and supervisory control and data acquisition systems, Ruth said he subscribes to Ashby's Law of Requisite Variety. This law states that “in any given physical system, the part of the system with the greatest flexibility will control the system. That concept should

be applied in all supply chains (and associated production systems) to the point that is realistic. But it's not going to be in the normal scope of a capital project approach. In many cases, it's going to require really looking at your approach to automation at a fundamental level, and measuring that across multiple projects to show improvement in value. The winning manufacturers will boost their adaptability with automation information and data analysis.”

For manufacturers to successfully achieve this on an ongoing basis, Ruth says companies will likely benefit by leveraging the expertise of a partner they can rely on to “examine the options, recommend a path, and work with their technologies. This is important because it's not going to be a one shot fits all kind of integration. It’s going to require a bit of evolving back and forth as things change to manage the change that's coming.”

Ruth cautioned that, even with this approach, it’s not a good idea to apply too much change too quickly. The rate of change has to be something you're comfortable with while maintaining a “deep bench of options” for support. This will be necessary because continuously confronting coming changes means you’ll need to be able to “touch and tweak things often to live in this new normal, because I think we're walking into something we haven't seen before. And we're not completely prepared to abandon the old ways of how we did things. And that change will be a challenge.”

10/29/20 10:19 AM

12 PERSPECTIVES AW NOVEMBER 2020

Artificial Intelligence Advances Food Safety

By Aaron Hand, Editor-at-Large for PMMI Media Group

M

achine vision has long found a place in food safety. But as data access increases and processing power improves, machine vision is finding even more opportunity through the added capabilities of artificial intelligence (AI).

To take one example, traditional machine vision tends to struggle to inspect for contamination in sun-dried tomatoes.

But it’s an application that’s well suited to AI. “Similar to a human, AI is very good at dealing with a lot of variations in whatever’s being looked at,” says Quinn Killough, senior business development manager for Landing AI, a company that provides end-toend AI platforms for manufacturing. “That type of application, because there’s so much variability in what a tomato could look like or what kind of contamination could be on it, it was a pretty tough machine vision problem in general. A human can do it easily. And it turns out AI can do it fairly easily as well. Being able to deal with all that variation in what you’re looking at, it makes it very well suited for AI.” As a general rule of thumb, if a human could come up with a decision in their head in less than a second, it’s something that AI could handle. But then why not stick with humans for the task?

“If you have a human out there inspecting products, they are subject to change in a lot of it. What they think might be a defective piece of food one day they might say is an OK piece of food the next day. They are impacted by a variety of things—they could be in a bad mood that day, or they could’ve forgotten their glasses that day, something like that,” Killough explains. “Machine learning will be able to perform at the best human’s ability consistently, 24/7. There’s no variation in the accuracy with which the machine learning model will look at something and provide a prediction.”

Killough describes a leak inspection meth-

2011_Perspectives.indd 12

od in which a packaged product is submerged in water with pressure added to the tank to try to pull air out of it as another example where AI fits well. “The human will sit and look for bubbles coming out of this package,” he explains. “With cognitive fatigue, they would eventually miss something, or something might get in the way of their vision and bad products would get through the production line. What we did was create an algorithm that can look at these packages and detect these bubbles consistently and work 24/7.”

Another inspection problem that traditional machine vision has struggled to deal with are skewed date codes on the bottoms of soup cans. “You need to make sure that you have the right date code on that soup tin, but because there’s ridges on the bottom, it gets printed and gets all skewed,” Killough describes. “A traditional system won’t be able to read that, and AI actually does it pretty easily.”

For this, Killough makes a distinction between the typical rules-based machine vision and the machine learning of AI. “The traditional way of doing it is hard coding with rulesbased algorithms—what the camera should be looking for,” he says. “It’s very limited in its capabilities because it’s hard coded so it

wouldn’t be able to deal with all the variations that I’m talking about in these applications.

Whereas machine learning powered machine vision is trained with a ton of images, so it sees all that variation. It learns the variation and learns to kind of accept it.”

Making AI easier

Though AI certainly has its benefits, deploying it can be a challenge if you don’t know what you’re doing, Killough says. “So we tried to tie it all together based on all the machine vision projects that we’ve worked on into this endto-end platform that essentially streamlined the whole workflow from project inception to deploying a model in production—and taking that deployed model and scaling it out across multiple facilities,” he explains.

Because too often engineers are spending up to 80% of their time just preparing and labeling data, Landing AI has put a lot of its platform’s focus on the data preparation side of things. “We streamlined that process to enable those machine learning engineers to collaborate with the subject matter experts on plant floor who actually know what defects look like and what they don’t look like.”

Landing AI was founded in 2017 by Andrew

10/29/20 10:19 AM

PERSPECTIVES 13 AW NOVEMBER 2020

Ng to help manufacturers move AI projects from proof of concept to full-scale production. Having worked in large tech companies like Google and Baidu, Ng saw the value that AI could bring to those with the data and technical competence to handle it. “But what he realized was that there’s this long tail of people who could benefit from AI that maybe don’t have the technical expertise or the data to be able to create AI solutions and get the value out of it,” Killough says. “So the idea behind Landing AI is really to enable that long tail of users to get the value out of AI.” That’s a profile that fits a lot of companies in the manufacturing space, where machine vision tends to be a high-value system, Killough notes. “We’ve seen a whole variety of adoption levels within customers,” he says. “There are ones where machine vision is already pervasive, but they still have problems that they need help solving. There are those who know they could benefit from machine vision, but don’t really know how to tackle it. And then there are those that haven’t really considered it, but they definitely can benefit from it.”

Landing AI tends to interact most with that middle group—those who know they can benefit but don’t really know where to start.

Pandemic push

With the COVID-19 pandemic making it more difficult for food producers to operate with their usual workforce levels, there’s been an even bigger push into discovering the capabilities of AI. The guidelines released recently by the Centers for Disease Control and Prevention for meat and poultry processing workers—including distanced workers and physical barriers—is just one example of how the food industry is expected to conduct its operations amid the pandemic.

The situation is leading in part to the increased use of robotics, but it’s also leading to more interest in AI. “We’ve certainly seen some additional interest for that reason,” Killough says, noting recent interest from key chicken producers. “They realize how vulnerable they are to situations like this. And now they’re thinking to the future of when this might happen again. Or just in the present

case, how long this is going to last currently.

Automation really helps with putting them to ease with some of those concerns.”

According to Leo Zou, director of communications for Landing AI, the company has been surprised at how advanced some of these companies are on their AI journeys. “We also learned some of the difficult challenges they face when integrating or managing their AI solutions, which leads to the work we do,” he says.

Trying to get a better sense of where manufacturers fall on the spectrum of integrating AI into their visual inspection systems, Landing AI is in the midst of a joint research study on the topic with the Association for Advancing Automation. “We wanted to really get a sense of where the companies are,” Zou says.

“Some of them are more advanced, some of them still haven’t even started, some of them are figuring it out.”

WOW! That was “Simply easy!”

This engineer just set up several ultrasonic sensors for a new machine line. Despite the varying ranges he had to set, he used a single software application. He set the distances. He adjusted gain.

He filtered out anomalies. And those settings will remain for future replacement sensors.

Programmable... ...Flexible... ...and SMART! XX Ultrasonic Sensors with FREE easy-to-use software. Ideal for level detection and control, mobile equipment, hoisting, & material handling applications.

2011_Perspectives.indd 13

www.tesensors.com/XXSonic

10/29/20 10:53 AM

14 PERSPECTIVES AW NOVEMBER 2020

Understanding Virtualization for Industrial Automation

By David Greenfield, Director of Content/Editor-in-Chief

A

t the virtual 2020 Ignition Community Conference, held by Inductive Automation, Mike Fahrion, chief technology officer at Advantech B+B SmartWorx, conducted a session that explained the use of virtualization for industrial automation applications. Though there has been plenty of coverage on the concept of virtualization in manufacturing applications (including this article published by Automation World: http:// awgo.to/crossroads), there remains a good bit of confusion around the topic. To help clear up this confusion, Fahrion’s presentation provided plenty of straightforward explanations.

In this article, we’ll highlight the main points.

Dedicated vs. virtual

To help set the scene for his explanation of virtualization, Fahrion offered several examples, such as buying a camcorder back in the 1990s or early 2000s when you wanted to record something on video, or buying an alarm clock to ensure you woke up on time, or buying a GPS device if you were going on a remote hike.

These are all examples of dedicated appliances we once bought to do specific things.

“But when we use dedicated appliances to build industrial solutions, things get complex and expensive in a hurry,” said Fahrion.

“When you build a solution using dedicated appliances, you keep buying more and more appliances. Then you have to figure out all the interconnections and integrations [between those appliances] and it becomes a very linear relationship. If you want to add another function, you add another appliance.”

That’s where virtualization comes in. With this technology we have access to “softwaredefined appliances running in common hardware platforms [so that] when we want to add a function, we simply add another software application to extend the value and the flexibility of the hardware we already own,” he said.

“This is ideal for today’s environment of digital transformation because we not only reduce the quantity of the hardware we need to buy, but we also increase our agility and the adaptability such that we can more easily respond to

2011_Perspectives.indd 14

changing business requirements. And [virtualization] allows us to do this without big rip-andreplace cycles and it reduces vendor lock in.”

From data centers to industry Fahrion noted that virtualization isn’t something new. “We’ve been doing it on servers and in data centers for years,” he said. In the world of data centers and servers, the way the virtual machine works is through the addition of a layer of software called a hypervisor that sits on top of a piece of computing hardware.

A hypervisor allows one piece of hardware to run multiple virtual machines. Fahrion added that Advantech B+B SmartWorx’s “virtual machines sit on top of that hypervisor so that each virtual machine bundles together an operating system, the application itself, and any of its dependencies, libraries, or configurations that are needed to run that application.

And these virtual machines are easily replicated across different hardware platforms and are easy to scale up or down.”

Relating this concept to industrial applications, Fahrion explained that the virtual machine on the hypervisor would not be in a climate-controlled data center but at the network edge in a NEMA enclosure or embedded inside of a piece of packaging equipment where it could be subject to higher temperatures and low air flow. This is where the concept of containers enters the picture.

Containers are a “leaner form of virtualization,” explained Fahrion, because they “share the host operating system rather than replicating the operating system in every container. Therefore, we only need one operating system sitting on the system for each container to hold the application and its dependencies, libraries, and configurations.”

He added that, if there are libraries in the operating system that are shared across containers, it is not necessary to replicate them in each container. “Containers are isolated from each other and from the outside world; we create interconnections over virtual networks within the containers or bridge them out to the outside world.”

Because each container essentially gets its own virtual network and has no access to outside sockets or other containers in a native fashion, Fahrion said that, if this set up is managed correctly, the use of containers can dramatically reduce the number of attack vectors on your network.

Additional advantages

Beyond the security advantages of containers, Fahrion said another major advantage is resiliency. “When you build one monolithic application that holds your user interface and your databases and everything else, if one part of that compiled application crashes, the whole thing is gone and needs to be restarted,” he said. “In a container, however, we isolate each of those functions from each other. This means that one crashed application doesn’t bring down the whole machine. We just need to restart that particular container, which can be set up to happen automatically.”

Another advantage Fahrion noted is portability. Because containers contain both the app and its dependencies, you can move these containers across hardware platforms regardless of whether its ARM or x86 or a large multicore processor or a single core edge processor. “This is critically important in the industrial IoT space because we’re typically designing for very long life cycles,” he noted.

“So if you need to replace your hardware five or seven years from now, you’ll find that you can’t buy that same edge companion box with the same processor and memory configuration and drives. But you still need your application to run on the new hardware seamlessly without any local dependencies. Containers provide that solution for you.”

Scale is another important feature of virtualization. Fahrion explained that, because new containers can be deployed virtually in seconds, it’s “very easy to deploy a single solution across thousands of pieces of hardware and thousands of locations,” he said. In this way, containers eliminate the issue of application working on one machine but not on another as well as the debug cycles associated with

10/29/20 10:19 AM

PERSPECTIVES 15 AW NOVEMBER 2020

correcting such problems.

Speed and agility are another set of advantages offered by containers. “If you need to update one of your virtualized, containerized applications, you can just stop that container and update it without taking down the higher piece of hardware or the rest of the applications,” said Fahrion. “Or maybe you want your applications to always update to the most recent version or maybe you never want that to happen and you want them to always stay fixed on a very specific version—either way that can all be done with a simple command switch. As often happens in the world of industrial IoT and digital transformation, we discover new use cases as we go, so it’s very common to want to add new features, like adding an artificial intelligence inference engine to the edge in a containerized solution. That’s very easy to do by simply adding another container—and you don’t have to worry about it impacting the rest of your application or what’s it’s going to do to your user interface or database because everything is isolated.”

2011_Perspectives.indd 15

Using containers enables “cloud native” architectures to be extended to the smart device edge. Each component of the system (database, logic engine, visualization, etc.) is an independent service. This enables components of the system to easily migrate up the stack as applications grow. Source: Advantech B+B SmartWorx

10/29/20 10:53 AM

16 NEWS

AW NOVEMBER 2020

Intel Targets Digital Transformation with New Processors

By David Greenfield

Director of Content/Editor-in-Chief

A

utomation World has covered developments around Time-Sensitive Networking (TSN) and the Industrial Internet of Things for several years now.

With its ability to manage multiple streams of high bandwidth network traffic and prioritize control data to ensure deterministic communications, TSN is poised to have a lasting impact on industrial Ethernet networking—as such, it’s a critical component of industry’s digital transformation.

As with any new communication technology advance, the need for underlying computing devices to be developed so that the networking devices housing them can be produced is the first major hurdle to cross.

And with the recent news from Intel, it’s clear that the number of TSN and Internet of Things (IoT)-capable chips on the market are increasing dramatically.

At the Intel Industrial Summit 2020,

the company announced the release of its 11th Gen Intel Core processors, Intel Atom x6000E series, and Intel Pentium and Celeron N and J series to bring new artificial intelligence (AI), security, functional safety, and real-time capabilities to edge computing users.

Intel’s 11th Gen core processors are designed for what Intel calls “essential IoT applications that require high-speed processing, computer vision, and low-latency deterministic computing.” New dual-video decode boxes in these processors allow the processor to ingest up to 40 simultaneous video streams at 1080p 30 frames per second and output up to four channels of 4K or two channels of 8K video. AI-inferencing algorithms can run on up to 96 graphic execution units or on the CPU with vector neural network instructions built in. With Intel’s Time Coordinated Computing and TSN technologies, 11th Gen processors reportedly enable real-time computing demands while delivering deterministic performance across a variety of use cases, such as mis-

sion-critical control systems, industrial PCs, and human-machine interfaces.

The Intel Atom x6000E Series and Intel Pentium and Celeron N and J Series processors are Intel’s first processor platform enhanced for IoT. Features include up to 2x better 3D graphics; a dedicated real-time offload engine; Intel Programmable Services Engine, which supports out-of-band and in-band remote device management; enhanced I/O and storage options; and integrated 2.5GbE TSN. These processors are designed to support 4Kp60 resolution on up to three simultaneous displays, meet functional safety requirements with the Intel Safety Island, and include built-in hardwarebased security.

In industrial applications, these processors are suitable for use in real-time control systems and devices that meet functional safety requirements for industrial robots as well as for chemical, oil field, and energy grid-control applications.

11th Gen Intel Core processors for Internet of Things (IoT) are enhanced specifically for essential IoT applications that require high-speed processing, computer vision, and low latency deterministic computing.

Source: Intel Corporation

2011_News.indd 16

10/29/20 10:18 AM

NEWS 17

AW NOVEMBER 2020

AI-Embedded Operator Interface App

By Luis Rodriguez Managing Editor

S

tratus Technologies has updated its ztC Edge portfolio, which includes the ztC Edge 100i and ztC Edge 110i, with new enhancements said to deliver an improved and more efficient multi-site deployment and provisioning experience of the company’s edge computing platform.

The ztC Edge is a virtualized, zero-touch, automated edge computing platform designed to help organizations increase operational efficiency by delivering zero downtime at the edge. Zero-touch refers to the ability to configure the zTC Edge automatically without the need for manual intervention. For more information on the ztC Edge, visit: http:// awgo.to/ztcedge.

According to Stratus, the new security, manageability, and performance enhancements introduced in this update include: • Security: A new cloud-based file repository, called the Stratus Cloud, has been introduced to the ztC Edge 110i. The Stratus Cloud allows partners and customers to securely transmit, store, and retrieve ztC Edge system preferences templates, says the company. In addition, the Stratus Cloud automatically authenticates users and groups using the same credentials as the Stratus Customer Service Portal

account, helping to save time.

• Manageability: The simplified system backup and restoration enabled by the Stratus Cloud and local storage capabilities will help companies save time by automating certain processes to reduce user error, according to the company. Different templates can now be created and archived for different use cases, workloads, or locations, helping to make commissioning systems more efficient and accurate. For example, organizations can use these templates to provision single or multiple ztC Edge platforms from remote areas. The latest version of the ztC Edge is also Microsoft Azure certified, with integration capabilities embedded in the platform for a simpler systems manage-

ment experience and faster time to value for customers, says Stratus.

• Performance: The ztC Edge 110i comes with expanded 64 GB memory capacity to support a broader range of memoryintensive industrial workloads. ztC Edge 110i platforms are now Class I Division 2 certified, making them safer to deploy in hazardous locations.

In addition, the ztC Edge platforms supports common operations technology and information technology protocols, tools, and standards, such as Simple Network Management Protocol and OPC UA. Stratus says this makes the products easier to integrate into, and work with, existing environments.

Organizations Join Forces to Address Digital Transformation Challenges for Oil and Gas

By Luis Rodriguez Managing Editor

D

oris Group, Schneider Electric, and Aveva have partnered to deliver digital twin technology to the upstream oil and gas markets with new offerings to improve asset performance, increase sustainability, and maximize return on capital projects.

The three companies will combine offerings to bring engineering capabilities, an

2011_News.indd 17

asset lifecycle software offering, and digital specialization to create a digital twin which the companies say will serve as a backbone for improving performance for the upstream sector. The new offerings are said to: • Bring new assets on stream faster using cloud-enabled software to improve collaboration and increase engineering efficiencies; • Deliver enhanced safety leading to better business outcomes; • Improve traceability through a single

point of accountability; and remote operations and production assurance through a digital twin that mirrors all aspects of the operating asset.

According to the companies, the structured, digital, and collaborative products across the lifecycle of projects will help oil and gas organizations address challenges like sifting through the large amounts of data—of various types—from different sources, which often leads to data inaccuracy and incompat-

• Enable

CONTINUES ON PAGE 19

10/29/20 10:18 AM

18 PMMI NEWS AW NOVEMBER 2020

COVID-19 May Boost Cloud and Edge Computing

By Kim Overstreet Content Strategist, Alignment at PMMI Media Group

A

ccording to a new report from PMMI Business Intelligence, 47% of leading CPGs and 46% of small- and mediumsized enterprises (SMEs) are currently utilizing cloud computing, while only 20% of leading CPGs and very few SMEs are utilizing edge computing strategies. However, the use of both have accelerated due to COVID-19.

Cloud computing enables manufacturers to access production data and controls, remotely and in real-time. By continuously uploading data to the cloud, manufacturers can obtain a comprehensive view of their operations, monitoring where products are, controlling what production lines are doing, and analyzing gathered data without the need to be physically present at the production site. Edge computing enables many of the same advantages of cloud computing, but without the option of remote access to data.

According to the report, “many manufacturers are uncomfortable with the idea of full remote connectivity into their operations and fear infiltration and potential sabotage from outside sources.” Edge computing was introduced to mitigate cloud security concern—data is still uploaded to a centralized repository, but one that must be accessed locally. A senior manager of engineering at a dry shelf goods operation said, “we do not allow online access to the control system; access with OEMs is on a case-by-case basis with multiple levels of approval.”

CPGs indicate the following elements are a “must have” before any discussion of remote connectivity becomes the norm: a virtual private network connection that is walled off from the factory network, in-depth approval from the information technology department, and a trusted partnership with supplier.

The advantages of cloud and edge computing may have become more appealing during the COVID-19 pandemic, as working from home has become increasingly common and manufacturers have turned to remote-access strategies as a means to reduce the number of employees that are required to be physically present at a manufacturing location.

Remote access to both individual machines

2011_News.indd 18

and the larger enterprise management system can allow at least some of the workforce to avoid the plant floor, while also enabling remote troubleshooting and maintenance from OEMs. In the June 2020 PMMI Purchasing Managers Index, the following four industries reported current remote-access use well above the median baseline. In addition, they also report expected future expansion of remote access capabilities, although each industries’ place on the remote access timeline varies.

Beverage: Current remote access usage for the beverage industry is 9.1 points above the average of all industries examined, while future usage is predicted to be 8.8 points above the average.

Food: Current remote access usage for the food industry is 1.1 points below the average of all industries examined, while future usage is predicted to be 1.5 below the average.

Personal care: Current remote access usage for the personal care industry is 5.3 points below the average of all industries

examined, while future usage is predicted to be 0.2 points above the average.

Pharma/Medical device: Current remote access usage in this industry is 5 points above the average of all industries examined, while future usage is predicted to be 1.5 points above the average.

Cloud and edge computing are best deployed by operations that already have fairly comprehensive Industrial Internet of Things integration and are gathering large amounts of data through integrated networks of sensors. The report suggests that, “OEMs and suppliers can assist manufacturers in identifying when the time is right to deploy cloud and edge computing, making these technologies a crucial component in the complex process of upgrading an operation to incorporate widespread automation.”

To access this free report and learn more about automation in production operations, visit: http://awgo.to/pmmiremote.

10/29/20 11:41 PM

NEWS 19

AW NOVEMBER 2020

CONTINUED FROM PAGE 17 ibility, as well as difficulties organizing that data and identifying trends; and help organization quantify, track, and, ultimately, reduce CO2 emissions as well as reduce overall pollution, which can be even more difficult with limited monitoring capabilities and no data-driven decision making.

“Our common aim is to support organizations on their digital journey especially in the current environment, helping them accelerate the use of digital technology, realize the value of a digital twin, and also work towards a more sustainable future,” said Craig Hyman, CEO at Aveva. “It’s never been easier to begin a digital transformation program, as access to cloud computing, great connectivity, a merged edge and enterprise combined with analytics and machine learning, means that the ability to digitally drive productivity improvements into the industrial world is now unprecedented.”

Robust Ethernet Networks Unmanaged Smoke and Fire Switches Managed Switches UL 864 Power over Ethernet (PoE)

Diagnostic Switches

RemoteVPN IP Routers

Media Converters

Complete your automation network with CTRLink’s wide range of cost-effective wired and wireless 24 VAC/VDC powered Ethernet connectivity products with panel or DIN-rail mounting • Managed and unmanaged 10/100/1000 Mbps Ethernet switches • Single mode and multimode fiber optic switches and media converters • Wired and wireless IP routers for secure remote access • PoE switches, mid-span splitters and injectors • Diagnostic switches for network troubleshooting • Custom configurations and outdoor-rated options available

Learn more at www.ccontrols.com/ctrlink 2011_News.indd 19

10/29/20 10:57 AM

20 COLLABORATIVE ROBOTS AW NOVEMBER 2020

Collaborative Robotics Expand In Scope

By David Miller, Automation World Contributing Writer

W

e all want to know what makes our co-workers tick and, perhaps, collaborative robots (cobots) are no different. Yet, for all the buzz about the growing prevalence of cobots in industry, there’s often a great deal of confusion over precisely how the term cobot is defined.

Therefore, as companies look to increase productivity, circumvent labor shortages, and reduce human contact in their plants with the help of cobots, it’s time to ask, “What does it truly mean for a robot to be collaborative?”

It’s important to note that there is no single, formal definition of what a cobot is.

Rather, ISO standards 10218-1 and 10218-2 set forth four potential characteristics of collaborative robotic systems. These collaborative capabilities—safety monitored stop, speed-and-separation monitoring, powerand-force limiting, and hand-guiding—can all be achieved through the use of sensors, control systems, and peripheral devices, some

2011_F1.indd 20

of which may already be integrated within a robot upon purchase, where others can be retrofitted to a pre-existing industrial robot.

"There is no hard line between collaborative and non-collaborative robots,” says Andie Zhang, global collaborative robots product manager at ABB. “Cobots are basically a subset of industrial robots with different features, and almost all industrial robots we provide have the possibility of becoming more collaborative. From the user's perspective, they should think about what the specific operational problem they want to solve is and what the best way to do so is. Picking an option always depends on your application."

Various approaches

Highlighting the variety of available cobots, ABB, for example, offers a multitude of different products. While the company’s YuMi robot, which is trumpeted as being “inherently safe,” may spring to mind due

to its small size, power, and force limiting capabilities, ABB also offers SafeMove, a software system that integrates with ABB’s IRC5 robot controller family to allow its pre-existing industrial robot lines to engage in both safety monitored stops and speed and separation monitoring. Simply put, by utilizing pressure-sensitive safety mats, light curtains, or laser area scanners as inputs, SafeMove enables industrial robots to either slow down or stop entirely when workers enter the cobot’s hazard envelope.

The key distinction here is whether or not an application requires a human to work so closely to the robot that there is potential for a collision. If so, such as in a situation where task changeover is frequent or workers are required to continue processing parts after a robot has finished handling them, cobots like YuMi (which allows for hand-guiding and power-and-force limiting) may be the best option. However, because the laws of phys-

10/29/20 10:18 AM

COLLABORATIVE ROBOTS 21 AW NOVEMBER 2020

As the development of collaborative robotic systems continues, the line between typical industrial robots and those deemed “cobots” continues to blur.

2011_F1.indd 21

10/29/20 10:18 AM

22 COLLABORATIVE ROBOTS AW NOVEMBER 2020

ics require these robots to be smaller and move slower to remain collision-safe at all times, speed and payload capacity may need to be sacrificed, thereby lowering throughput potential.

In contrast, if a robot is capable of working mostly on its own with humans occasionally entering its workcell, safety monitored stop and speed-and-separation monitoring technologies, which can be externally appended, may be preferable and come with the added benefit of being compatible with larger, faster industrial robots.

One technology company focused exclusively on transforming industrial collaborative robots into cobots is Veo Robotics. This company’s FreeMove system uses multiple camera sensors and an algorithmic computing platform to transform industrial robots into cobots. To read more about how Veo Robotics’ uses the ISO speed-and-separation monitoring standard to achieve its aims, read Automation World’s coverage of the technology at http://awgo.to/1093.

Epson Robotics offers small SCARA and six-axis robots that can be programmed to work in a collaborative fashion

2011_F1.indd 22

Other options and considerations

The term cobot is even more loaded than the nuances of ISO standards 10218-1 and 10218-2 would initially seem to suggest. Even beyond the specific technologies that enable robotic systems to become more collaborative, the concept of a cobot brings with it certain end-user perceptions and expectations apart from the product’s electronic and mechanical capabilities.

As Joe Campbell, senior manager of applications development at Universal Robots, points out, the cobot designation is as much about stripping away complexity and providing flexibility via easy integration, programming, and operation as it is about safety features. To meet these needs, Universal Robots’ business model is oriented toward ease of use. In fact, Universal Robots’ market niche has long been small- and medium-sized enterprises, contract manufacturers, and other companies who—due to risk aversion, skills gaps, or lack of capital—cannot adopt more fully automated systems.

“We’re selling double digit numbers of robots into companies that I previously never would have made a sales call on in my entire career because they never would have qualified before,” Campbell says. “For instance, I know a 22-man machine shop that now has ten robots. Before, I wouldn’t have ever marketed to them because they wouldn’t have purchased traditional automation. Now they’re a huge part of this explosion in interest.”

That’s why a company like Epson Robotics, which has yet to release its own cobot line, feels that it has learned from trends

in the collaborative safety space and has something to offer customers who are eyeing a cobot purchase. According to Scott Marsic, senior product manager at Epson Robotics, when new entrants look to purchase their first robot, it is often their need for an intuitive user experience, scalability, and a low-cost product that incentivizes them to choose a cobot, over and above the need to actually share a workspace with their machine. In response, Epson Robotics has released its all-in-one line of small SCARA and six-axis robots, which Marsic feels can fulfill the same fundamental needs that many cobots do, even without the collaborative safety features.

"The biggest feedback we've seen from people is that they purchase cobots because they see they're easy to use, easy to implement, and easy to place, but what they don't realize until after they've placed the cobot is that their throughput isn't going to be what they expected. They like the simplicity of the programming and the GUI (graphical user interface) that allows them to get up and running quickly, but they're not able to perform at the levels they really want to," Marsic says.

"What we've seen from our builders, our customers, and our distributors is that, in some cases, cobots are not being used the way they were designed to be used. What people really need is simply ease of use."

The trade-offs Marsic indicates are the result of the need for power-and-force limiting cobots to remain below a certain threshold of size and speed, ensuring they are collision safe at all times. He argues that the reductions in throughput that result from these slower speeds may ultimately hurt one’s bottom line, offsetting the initial labor savings the cobot allows for. Still, even though these restraints may affect smaller, power-and-force limiting cobots, advances in speed-and-separation monitoring are helping larger, faster industrial robots circumvent these boundaries.

For example, Fanuc’s CR series cobots, which use speed-and-separation monitoring, can reach speeds of up to 1500mm per second and offer payload capacities of up to 35kg, which is the highest on the market, according to Fanuc. Greg Buell, senior engineer at Fanuc, anticipates the trend continuing toward cobots with longer reaches, higher speeds, and greater payload capacities as speed-and-separation monitoring technologies continue to improve.

10/29/20 10:17 AM

COLLABORATIVE ROBOTS 23 AW NOVEMBER 2020

A CR-35iA collaborative robot from Fanuc working in tandem with a technician on an automotive headliner gluing application.

2011_F1.indd 23

10/29/20 10:17 AM

24 COLLABORATIVE ROBOTS AW NOVEMBER 2020

The dual-arm YuMi collaborative robot from ABB is touted as the world’s first truly collaborative robot.

Making a decision

According to Campbell, cobots have historically been smaller and more simplistic than general industrial robots, largely because the companies producing them early on were highly specialized and sought to sell them to small- and medium-sized enterprises with a need for highly intuitive features. However, now that their popularity and functionality has expanded and major robotics manufacturers—such as ABB and Fanuc—have begun trying their hand at designing and selling collaborative robotic systems, end-users can expect larger, faster, and more powerful cobots to continue to proliferate. As a result, potential purchasers should anticipate a more diverse landscape of choices, though this may turn out to be a double-edged sword.

On the one hand, as options multiply, it is likely that products that are more closely tailored to manufacturer’s individual needs will become more common. On the other hand, more careful consideration may need to go into parsing the alternatives to select the one that is best suited to a company’s particular application. This latter process will

2011_F1.indd 24

require keeping the trade-offs enumerated above firmly in mind.

Beyond that, it’s important to note that, even when investing in inherently safe, power-and-force limiting cobots such as ABB’s YuMi, some safety qualms may remain.

For instance, regardless of how collision safe a cobot itself is, if it’s tooling or the objects it is handling possess sharp points or jagged edges, humans working in proximity to it can still be injured. Similarly, while a cobot engaged in a machine tending operation may be able to stop if it collides with a human worker, that does not mean that the door of a CNC or other device could not still slam on an operator’s arm. Even in applications where fencing has safely come down, a box or other manipulated item dropped due to a momentary loss of air pressure to a pneumatically actuated arm could find itself sliding across the floor. As such, situational awareness on the part of plant floor workers remains important and performing a risk assessment before deploying any particular type of cobot is absolutely indispensable.

Finally, those interested in cobots should

keep a close watch, not just on individual robots, but the various peripheral and add-on technologies being developed and released to supplement pre-existing industrial robotic systems. As in much of industry, software for zoning and safety controls continues to take precedence in areas where physical barriers and other hardware would have once been required. In addition, products such as Touché Solutions’ T-Skin, a tactile safety sensor system which can be applied to the surface of industrial robots to allow them to come to a safe stop upon collision with human workers, as well as several advanced vision systems for speed-and-separation monitoring continue to be game-changers in the collaborative space, making faster, higher payload collaborative robotic systems ever-more feasible.

And for those who feel overwhelmed by the rapidly expanding suite of options presented by this seeming robotic takeover, it’s important to remember that whatever Hollywood films may have taught us, these cobots come in peace.

10/29/20 10:17 AM

AUTOMATION WORLD AW NOVEMBER 2020

Segmenting your factory floor network improves operations hen talking about an industrial enterprise, the term IIoT (Industrial Internet of Things) is always mentioned and is often overused. However, nearly everyone can agree that there always is a benefit to getting the “right” data in a “sustainable” fashion from “edge” devices to individuals who can use the data to make better business decisions. A risk is that too much data collection, without proper foresight, can create a situation where a plant Ethernet network can be rapidly overwhelmed due to poor design.

W

It pays to collect data from the factory floor

• Real-time downtime analysis from one location (“A Single Pane of Glass”) can show instantly where resources need to be applied to increase productivity. Long-term analysis of this data can point to maintenance trends, staffing shortfalls, or process bottlenecks.

• Older assets can be connected to the network and improve process uptime. Even older machines with just relay logic controls can be monitored with the right equipment.

• Gathering data isn’t just about the traditional cycle time reporting issues. Predictive maintenance information such as monitoring the vibration on motors has been proven to reduce costly downtime.

Managing Network Traffic is more important now than ever

Over the years, the number of devices on the factory floor has exploded. Often, networks were augmented as an afterthought without regard to problems that would occur down the road. Currently, many large networks have bottlenecks due to speed issues and the continued existence of unmanaged switches. Multicast protocols often initially meant for a small cell can inundate and overwhelm a network without the proper managed switches in place.

The Convergence of IT and OT

The IT world (Information Technology) and the OT world (Operational Technology) are coming together rapidly. Both sides have the same goals, but often go about the process in different fashions. Both sides always agree that a good balanced and segmented network is critical.

Sometimes this is achieved via a “top down” design by having versions of the office switches down to the factory floor, where special

Full Page Ad.indd 73

Figure 1 – Problems will occur if multiple machines with the same IP address allocation pattern were simultaneously plugged in to a plant network. consideration must be made for environmental factors such as heat and vibration.

Industrial Routers can provide effective segmentation and connectivity

How does an organization handle networking equipment which can come from the outside? It is quite common now for machinery to come in from an outside vendor or OEM. Is it asking “too much” to be able to keep the original IP address scheme? An industrial router or switch with NAT (Network Address Translation) capability may be a solution.

The multiple machine cell case

Consider that an OEM over the years has delivered 20 machines consisting of a PLC, HMI, and a VFD (Variable Frequency Drive).

Because they were manufactured originally as individual machines, the OEM used the same IP address allocation pattern. 192.168.1.1 for the PLC, 192.168.1.2 for the HMI, etc. (Figure 1)

What happens when all 20 machines need to be connected?

In the example above, if all machines were simultaneously plugged in to the plant network, IP address conflicts would happen. Some of the problems are documentation headaches, sudden introduction of multicast protocols into the greater network, and extra unexpected reprogramming of individual assets.

A device which has NAT capabilities (Network Address Translation) will help

Employing a switch or router with NAT capabilities means that a factory floor automation

engineer can design a table which gives a one-to-one correspondence from an internal address to an “external” plantwide address.

That way nothing needs to change on the edge while maintaining security and uniqueness at the plant network level.

Add security with firewall rules

Often another advantage with these types of devices is the fact that one can add firewall capability for even more security. For example, if there is a SCADA machine on the plant network that needs to just talk to the PLC only, rules can be made to restrict all other communications except for requests from the SCADA computer.

Routers and switches with NAT (and Port Forwarding) capability are only one way that networks can be segmented and made more secure. Many organizations have implemented VLANs (Virtual LANs) to segregate traffic. Make sure that you consult professionals on both the IT side and the OT side about working solutions to help improve the operation of your network and enhance security as your enterprise grows.

By John Kan, Motion Industries John Kan is Connectivity Product Manager with the Mi Automation Solutions Group/ Braas Division at Motion Industries.

MotionIndustries.com

10/29/20 11:37 AM

26 NEXT-GEN CONTROLLERS AW NOVEMBER 2020

New PLCs Gain Esteem as the Brains Behind the Machine Next-generation controllers offer multifunctional automation with more intelligence and connectivity, opening the door to new opportunitiees for machine builders and integrators.

Stephanie Neil, Senior Editor at Automation World

2011_F2.indd 26

10/29/20 11:42 AM

NEXT-GEN CONTROLLERS 27 AW NOVEMBER 2020

M

odern industrial machines must be able to adapt to new configurations, new materials, and shorter runs to accommodate an ever-changing product landscape dictated by consumer and end user demands. To accomplish this, machines are increasingly designed to be modular while allowing for integration into production lines.

And, with the Internet of Things (IoT) making its way into machines and onto the plant floor, there are even more aspects to manage and control. Though this can require machine redesigning, it also presents an opportunity for OEMs, integrators, and end users.

“Next-generation machine builders want to differentiate themselves,” said Vibhoosh Gupta, senior portfolio product manager for Emerson’s machine automation solutions business.

And the technology available now can provide that critical differentiation, as long as OEMs start to think differently. Specifically, he said to rip a page from the Tesla playbook. “Tesla is teaching us that the relationship between OEM and customer is not a one-time transaction. If a machine is smart, you can make it a multi-touch transaction by providing [new] capabilities and service to the customer.”

The big question is: How have the machine controls—the programmable logic controllers (PLCs)—evolved to accommodate the need for more flexibility, connectivity, and functionality? In fact, machine control technology has progressed tremendously over the years as suppliers add machine learning, artificial intelligence (AI), analytics, cloud connectivity, simpler programmability, and even virtual operating systems.

PLCs and programmable automation controllers (PACs)—which are similar in functionality to PLCs but use different programming interfaces—have long been thought of as specialized computers designed to collect data from inputs and then execute an action. But now that these controllers are being designed with more capabilities, they are increasingly being seen as multifunctional mechanisms that are the real brains of the operation.

2011_F2.indd 27

10/29/20 11:42 AM

28 NEXT-GEN CONTROLLERS AW NOVEMBER 2020

Of course, when it comes to brains it’s all about processing power—and maybe a little bit more.

Thanks to Moore’s Law, which simply states that processor speeds for computers will double every two years, industrial suppliers are now using faster, multi-core CPUs in their automation controllers. A multicore processor is a single integrated circuit that contains two or more processing units, each of which can read and execute program instructions, thereby offering parallel computing and better overall performance.

And by coupling multi-core technology with virtualization technology, the PLC platform can run multiple operating systems (OS) on the same processor, including the realtime operating system (RTOS) required for deterministic control.

Emerson, for example, recently introduced an edge controller, which is basically a PLC with embedded IoT capability that uses real-time virtualization to add analytics and cloud connectivity at the control level.

Within this controller’s quad-core CPU, two cores are dedicated to traditional highspeed deterministic control, and two cores are dedicated to another OS, like Linux, to run different applications in a safe and cooperative manner, making sure that deterministic control is not impacted by anything that happens on the Linux side.

Edge controllers like this will feed the brains of the machine with IoT information that adds to the overall intelligence and scalability. And, referring back to Gupta’s original comment, will enable that Tesla-like multi-touch experience between the OEM and the end user.

Adding an edge controller—along with many smart sensors and instrumentation— will also usher in a new way to make machines.

“In the future, instead of replacing machines, you can upgrade them over time with IoT,” said Rich Carpenter, general manager of product management for Emerson’s machine automation solutions business.

Pondering next-gen PLCs

For the most part, machine builders have settled in to their tried-and-true PLCs, rarely attempting to change to a new control system or upgrade the technology because, if it’s not broke, don’t fix it, right? That may have worked in the past, but now is the time for OEMs to adopt more advanced control

2011_F2.indd 28

technology that will not only provide a competitive advantage, but also position them for a digital transformation.

“To achieve the next level of machine performance, the control platform is going to have to be much more capable than the legacy PLC,” said John Kowal, marketing director for B&R Industrial Automation.

Manufacturers will not be buying the same machines that they did several years ago, simply because e-commerce and mass customization has changed the way products are designed and made. And that means the way the machine is designed and made must change as well. “It is going to require a change in mindset. You’re going to have to make your machines more adaptive, and

that starts with the capability of the control platform.” (Editor’s note: John Kowal passed away after this interview was conducted. More information about John’s passing can be found at http://awgo.to/NwYUv) Kowal pointed to the ability to engineer multiple machine applications within a single unified control environment.

In late 2019, B&R announced the integration of ABB robots into its automation portfolio. Blending robotics with machine control into one unified architecture will help execute smaller lot sizes for mass customization. In addition, B&R integrates a vision system into the machine controller so that it works on the same real-time network as the machine in order to respond faster.

Emerson PACSystems RX3i CPL410 programmable automation controller features a universal programming environment to provide application portability across multiple hardware platforms.

10/29/20 11:42 AM

NEXT-GEN CONTROLLERS 29 AW NOVEMBER 2020

Omron Automation Americas’ Sysmac AI Controller is said to help manufacturers reduce the risk of equipment damage and downtime by detecting issues early on, prompting immediate action to reslove them.

By merging robotics and vision with machine control, there is more precise synchronization. “That same PLC has the power to control all aspects of the machine, process our integrated vision data, control our track systems, integrate networked safety including collaborative robotics, run digital twins, you name it,” Kowal said.

Today’s controllers are multi-tasking machines—just like the systems they automate.

Take the Mitsubishi Electric controllers.

The MELSEC iQ-R Series is designed specifically for advanced applications around productivity, engineering, maintenance, quality, connectivity, security, and compatibility.

The iQ-F, on the other hand, is designed for machine builders. It is a compact PLC that still has some of the characteristics of the more advanced version. It is an all-in-one power supply, CPU, and I/O with built in features for high-speed counters, positioning outputs, Ethernet, and SD card slot, a safety extension module can be connected, as well as various communication modules including a CC-Link IE Field Network intelligent device station module.

“It is designed to be an all-in-one unit with everything you’d need from a controller,” said Lee Cheung, product marketing engineer for Mitsubishi Electric Automation. In addition, the latest generation of the controller enables machine-to-machine communication between iQ-F CPUs without

2011_F2.indd 29

any programming.

“If you want to connect PLCs or devices, [typically] the programmer would have to write a program just to do the communication and handle data transfers and handshaking to make sure the data passes back and forth,” Cheung said. “But with this functionality built in to the CPU, all the programmer has to do is use a wizard-based drop-down menu to select what data is to be transferred.”

Mitsubishi Electric has also made it easier for the user to see the status of the machine via a built-in web server on the PLC. “And we’ve made it possible to create custom web pages,” Cheung said. “So OEMs can create their own web page that shows all of the information as it relates to the machine.”

The next-generation controller will have even easier usability, more flexible connectivity and communications, and some of the advanced functionality that is affiliated with Mitsubishi Electric’s higher performance PLCs, including even more coordinated motion control. “Packaging machines, for example, rely on high speed and high accuracy, and all of the axes have to be coordinated. And this is one of the key features of iQ-F and one of the reasons that a lot of our packaging customers use this product,” Cheung said.

Beckhoff Automation also has an integrated offering as part of its TwinCAT 3

automation software for PC-based control.

The company’s TwinCAT Vision software adds image processing to a universal control platform that incorporates PLC, motion control, robotics, high-end measurement, IoT, and human-machine interface.

“When you have an external vision system it grabs an image, communicates over fieldbus to the controller and, after processing, the controller may issue resulting commands to a robot,” explained Mark Ruberg, packaging industry market manager for Beckhoff USA. “So there is latency in the communication from the camera to the processor.

Beckhoff’s TwinCAT Vision has removed all communication latency by embedding the vision algorithms into our real-time kernel.

Thus, control loops around vision can be in microseconds as opposed to milliseconds, an order of magnitude faster.”

With its introduction of the ctrlX Automation platform, Bosch Rexroth claims to have done away with traditional boundaries between machine control systems, information technology (IT), and the IoT. It’s a more flexible and scalable platform, providing both centralized and decentralized automation topologies with the help of a Linux RTOS, open standards, app programming capabilities, web-based engineering, and a comprehensive IoT connection. According to Bosch Rexroth, the ctrlX Automation platform combines the latest engineering software tech-

10/29/20 11:40 PM

30 NEXT-GEN CONTROLLERS AW NOVEMBER 2020

Bosch Rexroth’s ctrlX Automation platform features open software architecture, a wide choice of programming language options, and app-based functionality.

nologies with all PLC and motion tasks. Software functions are combinable in any number of ways with ready-made, customized and customizable apps—which could be created

by Bosch Rexroth, its customers, or thirdparty suppliers in a variety of programming languages such as C++ or IEC 61131, script languages such as Python, or new graphical languages such as Blockly.

The network and the need for speed

Speed in the fieldbus network is also important because all of this processing power doesn’t matter if the data gets stuck in traffic. Beckhoff’s EtherCAT, which was developed in 2003 and has an independent technology group with over 5,600 members, is 100% deterministic. In 2018 EtherCAT G was announced, offering Ethernet transmission rates of 1Gbit/second. EtherCAT G10, currently in development, delivers 10 Gbit/ second data rates.

“EtherCAT is still the fastest industrial

2011_F2.indd 30

fieldbus available, but data transmission needs are constantly increasing for vision, analytics, machine learning, and communication to the cloud, driving greater bandwidth requirements,” says Ruberg. “EtherCAT G and G10 are there to fill this developing need, before it becomes a bottleneck.”

Carrie Lee, product manager of controllers at Omron Automation Americas, echoed Ruberg when she said, “EtherCAT has great network performance. It is super fast, and moving into the future it streamlines what we are trying to do.”

What Omron is trying to do is create a data sharing environment that a controls engineer can easily understand without having to become an IT expert. Through its Sysmac Studio and Integrated Development Environment (IDE), Omron provides a single operating environment to setup, program, debug, and maintain an entire machine system. It’s one software suite for configuration, logic, motion, vision, safety, drives, networks, and I/O. Last year, the company

announced the Sysmac Artificial Intelligence controller that integrates machine learning into an edge-level industrial controller. It runs in parallel with the standard controller, sharing a backplane to leverage machine learning and AI to monitor what is happening in the machine and to detect something out of the ordinary in order to react to it programmatically. “It means when it detects that something happened, rather than shutting down the line or wasting product, the machine will detect the anomaly and go to an alternate run mode to protect the product and processes,” Omron’s Lee said.

B&R has its own answer to network speed.

First, it starts with I/O slices with their own processing power inside. “It’s like the PLC distributed down to the I/O slice with fast response time [because] it’s not going up to the CPU to make a decision, it’s doing it right there,” Kowal said.

B&R, like many other automation suppliers, is also adding OPC Unified Architecture (UA) over Time-Sensitive Networking (TSN) to its

10/29/20 11:42 AM

NEXT-GEN CONTROLLERS 31 AW NOVEMBER 2020

automation portfolio. OPC UA is a platform independent serviceoriented architecture that provides the security and the semantics for multi-vendor machine-to-machine communication. TSN is an IEEE 802.1 defined standard technology that provides deterministic messaging on standard Ethernet. And OPC UA over TSN enables high-performance motion control traffic and bandwidthintensive IT traffic on a single cable without interference between them. (For more information on TSN, see: http://awgo.to/yQhpQ) For Rockwell Automation, OPC UA over TSN is not adding speed and determinism to its own EtherNet/IP reference architecture, which company officials say is designed to ensure the network is not overloaded. But it could solve a couple of problems inherent to the automation community.

“One is communication from controller to controller when supplied by different vendors,” said Paul Brooks, Rockwell Automation’s manager of technology business development. “As an industry we’ve never agreed on a single mechanism for controllers to talk to each other. The second thing is, as a community none of us have a good solution to communicate from a device to software applications. Communication from the controller to software apps is a well-solved problem, we have no problem getting information out of the Logix controller into a software app and into the cloud. But if you have a Kinetix drive it is a more difficult problem. The OPC community is working to solve the communication from an automation device to software applications…making it easier to get information out of those devices.”

And the bigger opportunity is the ability to seamlessly move machine information to the cloud, which can increase a recurring revenue stream for an OEM. “That means they can take a much greater degree of responsibility for ongoing maintenance support,” Brooks said.

There are other ways to collect that information now, of course. Mitsubishi Electric’s iQ-F controllers, for example, integrate with the company’s IoT gateway, so that the PLC can have connectivity to the Internet and push data to an online portal that allows the OEM to manage all of the machines in the field through a centralized point. “OEMs can see all of the different usage information about each machine as well as OEE stats at each location so they can give recommendations when they see that a machine is underutilized or overutilized. It also allows them to do remote maintenance through a tunneling functionality,” said Cheung.

Not your father’s PLC

And that brings us back to the theme of multi-touch service based on more capability embedded within the PLC. It’s what Emerson calls a “true” edge controller, and it truly changes the definition of what a PLC can do these days.

In fact, with so much power, intelligence, and speed built-in to automation controllers, B&R’s Kowal said the name “programmable logic controller” a bit obsolete these days. “I guess the term PLC today is kind of like my parents calling the refrigerator the ice box,” he said.

2011_F2.indd 31

10/29/20 11:43 AM

32 CASE STUDY AW NOVEMBER 2020

Data: It Does a Milk Producer Good Transforming raw materials into a variety of milks and ice cream mixes, Agropur lacked the data needed to improve its operations. An integrated control and information system from Rockwell Automation provided the needed visibility.

By Aaron Hand, Editor at Large

T

he dairy industry has long been at the forefront of using Big Data to breed the best cows for milk production.

But when it comes to turning that milk into other products, like cheese or butter or ice cream, the data needed to optimize production can be lacking.

That was the case not long ago at the Agropur Dairy Cooperative, which works with more than 3,000 dairy farmers to transform some 1.5 billion gallons of milk each year into a variety of dairy products.

Agropur’s largest facility in Don Mills, Ontario, turns raw ingredients into various types of milk and ice cream mixes, pasteurizing, processing, and packaging enough dairy products to fill at least 30 trucks each day.

Though machines and controls kept pro-

2011_F3.indd 32

Agropur will provide mobile access to production data to improve decision-making on the plant floor.

duction running, the Don Mills facility struggled to turn data into the information needed to continuously improve operations. “All the requests from operators and managers throughout the year required 2,500 hours of manual, post-shift data entry,” says Headley Hamilton, industrial process manager at Agropur, describing the labor-intensive process. “And demand was growing. When I considered the future of the facility, I knew we needed modern technology.”

With some of the automation systems nearing obsolescence, Hamilton was spending too much of his time putting out fires— dealing with nearly daily reports of equipment issues or downtime—rather than turning his focus to automation improvements.

If the system did crash, it was difficult to

know where the latest backup was. “With seven maintenance laptops across the facility, there was no way to know whether or not you were rebooting with the most recently modified program,” he explains, also noting that the old system was backed up only once per quarter. “You can’t optimize a plant when playing catchup.”

Planning for the future

Hamilton knew he needed a standardized, plantwide platform—one that could seamlessly share intelligence and learnings across facilities. Agropur opted for an integrated control and information system from Rockwell Automation, deployed by Grantek, a solution partner in Rockwell’s PartnerNetwork program. “We saw it as the best solution

10/29/20 10:14 AM

CASE STUDY 33 AW NOVEMBER 2020

for modernizing our facility from the receipt of ingredients to the moment end product heads out the door,” Hamilton says.

The platform included Allen-Bradley ControlLogix controllers, PowerFlex drives, and PanelView human-machine interface (HMI) hardware from Rockwell. Each HMI ran Rockwell’s FactoryTalk View Site Edition software on a virtualized server, establishing the standard for all additional software. This created the foundation for converting Agropur’s data into actionable information.

To get the most out of the new control platform implemented as part of the project, FactoryTalk Metrics software measured overall equipment effectiveness (OEE), which could be used to benchmark production capacity for the process lines. The system collected performance data that could help determine whether another processing line was needed to increase capacity or current equipment still had capacity.

An aggregation and analysis system would then help operators visualize data from the various sources across the facility and provide reports as needed. But Agropur first reduced the growing complexity of the new control

system by installing FactoryTalk AssetCentre software to manage automation assets, ensure version control, and keep up-to-date documentation. The seven maintenance laptops spread across the plant were also reduced down to one.

“The initial control and OEE deployments laid the foundation at Don Mills. FactoryTalk VantagePoint software from Rockwell Automation then provided a new level of access to all data from disparate systems across the entire facility,” Hamilton says. “The software exposed what occurred on the plant floor to the employees in charge of making continuous improvements.”

Supervisors were also able to check status updates and see how production was running, and email reports were automatically sent for each shift, with updates about the process.

Continuous improvements

Various teams at Agropur have been able to use the new intelligence for making continuous improvements to their production processes. For example, by creating benchmark reports and estimating the benefits of new hardware, one team was able to achieve a 30%

reduction in lube consumption for the lines.

“Having data at hand becomes the route to insight for any facility, and it’s recognized by everyone,” Hamilton says, emphasizing the benefits of information to make decisions.

“On one filler alone, we’ve improved efficiency by 25% over a three-month period.”

Visibility was also the key to reducing downtime. Before making equipment investments for production lines to increase processing, supervisors could identify opportunities for increasing capacity. One discovery was that lunches, breaks, and meetings caused more than 33 hours of downtime. Changes to scheduling made employees’ time more productive.

Hamilton is looking to make access to the data even easier through mobile capabilities.

“Information-based collaboration and decisionmaking have quickly been adopted, and now we want to take our common platform further,” he says. “Exposure to information throughout the facility on mobile devices is the future of realtime manufacturing intelligence.”

New control system and OEE deployments enabled Agropur Cooperative to benchmark production capacity for its process lines. Source: Rockwell Automation

2011_F3.indd 33

10/29/20 10:14 AM

34 INDUSTRY-SUPPLIED CONTENT AW NOVEMBER 2020

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.

By Horst Messerer, Product Manager, Helukabel

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 space-saving, highperformance, 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 100BASET1, as the application lengths are < 50 ft (15 m).

In order to make the SPE suitable for indus-

2011_F4.indd 34

trial use, and to help shape the technological changes, we joined the SPE Industrial Network (https://single-pair-ethernet.com).

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 system 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.

How does 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 up 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):

This illustration depicts how Single Pair Ethernet allows the extension of Ethernet communications to field level devices such as sensors and transmitters.

10/29/20 11:40 PM

INDUSTRY-SUPPLIED CONTENT 35 AW NOVEMBER 2020

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.

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

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 max. 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.

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 on weight, this will enormously increase data speed.

For process automation, with 10BASE-T1L,

2011_F4.indd 35

How Single Pair Ethernet’s Power Over Data Line capability enables parallel power supply and data transmission. These classifications are for end devices up to a maximum of 50 Watts power transmission.

10/29/20 10:14 AM

36 NEW PRODUCTS AW NOVEMBER 2020

Mobile Robot Moves Payloads Up to 250 kg

Omron Automation Americas, www.automation.omron.com/en/us The LD-250 mobile robot is built with a sturdier metal frame that can withstand unintended external impacts and more demanding duties. It can automate the transportation of bulky materials such as transmission blocks, seats, or wire harnesses in the automotive industry, for example, as well as voluminous packaging materials in the food and commodities industry. The robot is said to help companies that are increasingly urged to shift workers from material transport operations to other higher value-added tasks. When combined with Fleet Manager, software that enables the control of multiple mobile robots with different payloads through one system, manufacturers can realize a more flexible and optimized autonomous material transport system, according to Omron. The robot can also be customized with conveyor tops, courier systems, and adaptive material handling mechanics to create a system that best meets user needs.

Machine Vision Camera Offers NIR Imaging

Allied Vision Technologies, www.alliedvision.com The Alvium 1800 U-501 M NIR (near infrared) is a USB3 Vision camera equipped with ON Semiconductorâ&#x20AC;&#x2122;s AR0522, enabling high-quality imaging at 5.0 megapixel and 67 frames per second with NIR enhancement. Other features include on-board image processing, a USB3 Vision interface for GenICam SFNC features, a platform concept that enables the use of different camera models with common software, a Micro-B USB 3.1 Gen 1 connector with screw locks for industrial applications, precise sensor-to-lens mount alignment, standard M3 mounting holes for top and bottom mounting, standard M2 mounting holes for front mounting, and industrial performance for both embedded and machine vision applications.

Cameras are available as bare board, open housing, or closed housing, with a choice of S-Mount, CS-Mount, or C-Mount.

Advanced Power Quality Meter

Schneider Electric, www.schneider-electric.com/us The PowerLogic ION9000T features high-speed transient capture capabilities to help critical facilities avoid outages, equipment damage, failures, and interruption of operations. The meter is capable of both impulsive and oscillatory transient detection capture with up to 10 MHz sampling (>100 ns duration, 10 kV) on four phase voltages, according to Schneider Electric. The meter also has third-party certified Class 0.1S accuracy, and twice the precision of existing energy standards, to unlock new possibilities for energy savings and to ensure the unit can comply with the highest performance for revenue grade applications. The power meter is designed to align with grid cybersecurity policies, which is said to help eliminate vulnerabilities to critical power assets and systems.

Wall-Mount Enclosures for Industry 4.0

Rittal, www.rittal.com/us-en The AX and KX enclosures feature a simpler and faster assembly and component installation, greater flexibility, and enhanced safety. Panels can be removed individually with no need for the usual disassembly work. According to the Rittal, it is also easier to install doors and cam locks, and can be done without tools. The wall mounting bracket can be screwed into place from outside the enclosure without impacting its protection rating. For maximum space availability, the enclosure features larger gland plates, creating a third more space for cables. In addition, integrated locators enable simple, precise and time-saving incorporation of the interior installation rails.

2011_Products.indd 36

10/29/20 10:13 AM

NEW PRODUCTS 37 AW NOVEMBER 2020

Integrated XY Stages with Mechanical Bearings

PI (Physik Instrumente), www.pi-usa.us These integrated XY stages are engineered for higher loads. Stages are available with three-phase linear direct-drive motors for higher speed and ball screws for higher push/pull forces, respectively. Available with nanometer resolution linear encoders, the stages are well suited for applications in biotechnology, industrial automation, laser processing, and flat panel display testing and manufacturing. The integrated mechanical design allows for a lower profile and improved geometric performance, when compared to modular XY-stage assemblies of two single axis translation stages bolted together.

Due to the improved support, planar XY tables are stiffer and flex less compared to XY-combinations of single axis linear stages, according to PI.

Wet Gas Flow Sensor

Fluid Components International, www.fluidcomponents.com Gas Master Sensor for the ST80 Series flow meters delivers accurate, repeatable gas flow measurement in the presence of moisture and condensation droplets. Suitable for use in entrained moisture and rainshielding applications, the WG sensor configuration features a mechanical design that shunts moisture, condensation, and water droplets away from the thermal flow sensor, thus maintaining an accurate gas flow measurement while minimizing errors from a cooling effect on the sensor that might cause a spike or false high reading, according to the company. The Wet Gas option can be used in applications that have moisture entrained in the gas (annular mist) or for protection against down-the-pipe rain in larger, vertical stacks. It relies on standard thermal constant power technology and optimizes the sensor head design and installation to minimize or prevent condensation from contacting the sensor.

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 worldwideâ&#x20AC;&#x201D;supports 21 LTE bands, unlocked for global use Google-certified and Android Enterprise Recommended

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

2011_Products.indd 37

10/29/20 11:02 AM

38 NEW PRODUCTS AW NOVEMBER 2020

All-in-One IIoT Controller

Exor, www.exorint.com/en The EX700 series of controllers provides multiple functions in one unit. Based on the company’s X Platform, the Industrial Internet of Things controller can act as a browser, with an industry standard web engine running Chromium; as a gateway, with up to three Ethernet networks; an OPC UA pub/sub server and client, with time-sensitive networking connectivity and multiple protocols; as a human-machine interface with multi-touch operation in a high-resolution display; and as a programmable logic controller, with Codesys V3 with Internet stacks to function as a master through major protocols.

Other features include system and project rapid boot-up, OS Linux RT, multi-touch and gesturing; and up to a 2,100,000 pixel display.

Two-Phase Digital Stepper Drives

AutomationDirect, www.automationdirect.com Leadshine two-phase digital micro-stepping drives with micro-stepping motor movement and anti-resonance for optimal torque provide smooth motion with low motor heating and noise. The drives accept a wide range of input voltages (12-110 VDC, 18-80 VAC) and provide over-voltage and overcurrent protection, motor auto-configuration on power up, and soft-start at power on. Motor output current ranges from 0.3 to 7.2 A. The drives support NEMA 11, 14, 17, 23, 24, 34, and 42 frame size step motors with pulse input frequency up to 200 kHz. All drives support step and direction control; some models also support CW/CCW. DIP switches are used for built-in self-test, microstep resolution selection, current level selection, and optional idle current reduction.

Strain Gauge Load Cell Transmitters

Acromag, www.acromag.com TT351 load cell and strain gauge signal conditioners use software to select from a variety of sensor measurement options. A USB port simplifies setup on a Windows PC or Android mobile device and can be used with the company’s Agility app. Software menus help users set the sensor type, bridge configuration, excitation source, filtering level, and I/O ranges. Advanced capabilities allow fine tune scaling of I/O signals, adjustment of excitation levels, and bridge calibration. Universal output supports six ranges including 4-20 mA, 0-10 V, and ±10 V. Flexible power systems accept a 9-32 VDC supply at the terminals and a rail power bus option can supply multiple units from a single connection or establish redundant power. The narrow 17.5 mm housing mounts on a DIN rail. The unit’s input circuit allows true six-wire bridge measurement and includes an adjustable bridge excitation supply (four to 11 VDC) with a remote sense feature.

Water-Resistant PoE Bridge

Swift Sensors, www.swiftsensors.com The Power over Ethernet (PoE) Standard Bridge 1011 is built to withstand washdown procedures and exposure to chemicals, making it suitable for pharmaceutical manufacturing, food and beverage manufacturing, wastewater treatment facilities, and refineries. After power-on, the bridge can automatically identify all sensors within range, while the Swift Sensors Console can be used to configure individual sensors or groups of sensors, with no wires to connect and no software to install. The system is 100% cloud-managed and the bridge securely transmits sensor data to the Swift Sensors Cloud using 256-bit AES encryption.

2011_Products.indd 38

10/29/20 11:40 PM

NEW PRODUCTS 39 AW NOVEMBER 2020

Wire-Actuated Position Sensor for Hydraulic Cylinders

Siko Products, www.siko-global.com The SGH10L position sensors are for applications where almost no stroke loss is acceptable when integrating the sensor into the cylinder. This sensor uses a lateral mounting on the hydraulic cylinder in a specially developed housing rather than in the cylinder base. The system is fixed to the cylinder by a hydraulic screw connection and the cable is guided into the cylinder and redirected towards the piston head, where the cable is then screwed in, thus, only the installation space for the sensor ear is required in the cylinder. The sensor is only a few millimeters in size. According to Siko Products, sensors with this design increase the flexibility of hydraulic cylinders design with integrated position measurement.

Modular Safety Gate System

Pilz Automation Safety, www.pilzusa.com The modular safety gate system offers individual safety gate products tailored to the requirements of varied applications. The system features rapid diagnostics capabilities, additional control, and pushbutton elements, and an optional escape release. According to Pilz, different components can be provided and combined to fit the necessary application, allowing users to achieve an individual safety gate system tailored to the respective application. The system also includes the safety gate sensors PSENmlock with series connection for the safety gate sensor. Used in combination with the companyâ&#x20AC;&#x2122;s Safety Device Diagnostics, targeted control of up to 16 individually controlled switches or gates is possible.

BiSS Interfaces for Motor Feedback Kit Encoders

Posital-Fraba, www.posital.com Magnetic Kit Encoders support the non-proprietary open-source Bi-Directional Synchronous Serial (BiSS) Line communication protocol. The single-cable technology used involves the transmission of power and encoder signal in a single cable. This reduced cabling minimizes costs, while the fewer number of connectors reduces susceptibility to connector failures. A special feature of the BiSS Line interface is the implementation of the Forward Error Correction function, which is said to improve availability of data communications, even with faulty cables and plug connections. A four-wire system (with separate conductors for communication and power supply) or a two-wire variant (with combined communication and instrument power supply on a wire pair), are also available, based on the same communications protocols.

Rotary Lobe Pumps

Alfa Laval, www.alfalaval.com The OptiLobe 10 and OptiLobe 50 pumps are available in four sizes to meet the requirements of lower flow rates and higher production capacities. The pumps are suitable for general applications requiring low-shear operation and gentle handling of delicate products with easier serviceability, according to Alfa Laval. These pumps allow for heating/cooling front covers for processes in which products tend to harden at low temperatures. Seal faces have direct contact with high-velocity product media, which helps ensure a fast and secure Clean-in-Place process, reducing both cleaning time and contamination risk. According to the company, the pump design helps to maximize pump efficiency and to reduce pulsation and noise emissions, as well as reduce the possibility of product damage by internal product recirculation. Factoryset shimming simplifies roto changing maintenance, with no further adjustment or retrimming needed.

2011_Products.indd 39

10/29/20 10:13 AM

40 NEW PRODUCTS AW NOVEMBER 2020

I/O for the IIoT

Opto 22, www.opto22.com The groov RIO is an intelligent, Ethernet-based I/O unit that combines multi-signal, multifunction sensing with Power over Ethernet edge data processing for instant Industrial Internet of Things connection to real-world signals. According to Opto 22, the unit can quickly connect traditional wired switches and sensors directly to Ethernet networks, software applications, and cloud platforms without intermediary control or communication hardware, such as programmable logic controllers, programmable automation controllers, or PCs. The unit is completely standalone and software-configurable through a browserbased interface. It can be installed and operated independently, using its embedded software tools and protocols to share data instantly across the organization.

Enterprise-Level Remote Monitoring System

Honeywell Thermal Solutions, www.thermalsolutions.honeywell.com Thermal IQ Optimize provides real-time analytics and fault modeling with early event detection at the plant, equipment, and process levels to keep thermal process equipment running safely, efficiently, and effectively. Based on the company’s Forge asset and process performance models, the system extracts data from combustion equipment and thermal processes across the enterprise to provide a high-level view of thermal process performance through visual analytics. The asset performance management platform allows users to drill down into the data of individual assets for an in-depth analysis, enabling them to more quickly and easily identify anomalies in equipment function or processes, and determine their impact on enterprise efficiency.

High Resolution Line Scan Imaging

Teledyne Dalsa, www.teledynedalsa.com The Linea HS 32k camera uses two 16k/5 µm TDI arrays with pixel offset to capture two 16k/5 µm images in real time, which are then reconstructed to achieve a higher resolution image of 32k/2.5 µm. This up-conversion reportedly enhances detectability of subpixel defects.

One advantage of this technology is that existing lighting and 16k/5 µm lenses can be used without impacting the camera’s responsiveness and MTF (modulation transfer function) with a smaller physical pixel size. This means that OEMs can integrate this camera into existing systems to achieve much higher performance without needing to change any components.

The camera provides up to 150 kHz line rate in 32k/2.5 µm resolutions, or 5 Gpix/s with very low noise and high sensitivity. It also features active pixel assisted alignment and a Camera Link HS fiber optic interface for high reliability and long cable data transmission. The camera is compatible with the Linea Xtium2 CLHS series of high-performance frame grabbers.

Small Flame-Proof Motors

ABB, www.abb.com Low-voltage IEC flame-proof motors in frame sizes 80—132 offer the same safety and efficiency features usually found in ABB’s larger models. These motors are suitable for use in hazardous and explosive environments, typically found in the chemical, mining, and oil and gas industries. The added option to attach an auxiliary terminal box enhances safety in applications where sensors or anti-condensation heaters are needed, because it keeps the auxiliary connections separate from the motor supply terminal box, according to ABB. These motors are available in IE2 and IE3 efficiency classes, are supplied with ATEX and global IECEx certifications, and are certified for use with variable speed drives.

2011_Products.indd 40

10/29/20 11:39 PM

FINANCE VIEW 41 AW NOVEMBER 2020

Practical Advice to Increase Manufacturing Profitability

By Larry White

CMA, CFM, CPA, CGFM lwhite@rcaininstitute.org

Executive Director, Resource Consumption Accounting Institute (www.rcainstitute.org)

Top management must demand relevant and actionable information that will aid their fellow managers in making innovative and quality business decision.

2011_FinanceView.indd 41

F

or many years, this column has urged accountants and finance professionals to step up their game as business partners to all parts of the organization. With small and mid-size manufacturers, there is a tremendous need for accountants to move beyond financial reporting and budgeting for control to help every area of the business understand and improve the monetary impact of operations on profitability—whether it is in manufacturing, warehousing, marketing/sales, or personnel. The function most often missing from the accounting repertoire is creating information for internal decision support. Why? First, because it is barely taught in accounting curricula; and second, because most accountants start out in auditing and auditors don’t care about internal decision support, only external financial reporting.

I’m thrilled to announce that a book titled, “Profitable Expectations: An Accoutant Rising to the Challenge” has been published that tells the story of a traditionally trained accountant working as a controller for a manufacturing company who moves through a process of enlightenment (yes, that means guided by a spirit) to become an effective business partner. The story is fictional, it is very engaging, and it includes highly readable explanations of the approaches and thinking used to create actionable internal decision support models and information. Avid readers can explore a link to a spreadsheet that has a functioning model of the new thinking used by the story’s company. “Profitable Expectations” is comparable to Eli Goldratt’s “The Goal,” which illustrated constraint and throughput thinking. “Profitable Expectations” shows the value of modeling operations purely for internal decision support information that reflects operational and economic reality, not financial reporting rules.

Whether your business is large or small, this book has universal application as a guide for accountants to become better business partners and bring the power of internal decision support modeling and monetary insights to bear on improving profitability and the teamwork of your organization. “‘Profitable Expectations: An Accountant Rising to the Challenge’ is the story of a thirtysomething controller with a traditional, financial

accounting background who successfully makes the transition from an efficient “bean counter” to an effective “bean grower” and meets the challenge and expectations of her CEO. After a stint in public accounting, Marcella DeCou had been the controller of PlumbCo, a $20 million manufacturer and distributor of plumbing products, for three years when retired Admiral Alex Johnson took over as CEO. His view of a financial executive’s role was quite different from that of her previous boss. Johnson expected his controller to not only be an effective administrator, but a value-adding member of the company’s management team. The story follows DeCou as she works with other members of the company’s management team, as well as with an elderly muse she met through the Institute of Management Accountants, to better understand her company’s business processes, build trusting relationships with her peers, develop valuable leadership skills, use causal modeling to gain a deeper understanding of the economics that underlie PlumbCo’s business, and become a decision leader who plays a major role in guiding her organization into a more profitable and sustainable future.”

One essential message in the book for manufacturing CEOs is that the prime mover behind a controller becoming a value-adding member of a company’s management team was the CEO’s expectation that she become one. If accountants don’t know they are expected to help grow value, they will be content to sit back and do historical reporting. Top management must demand relevant and actionable information that will aid their fellow managers in making innovative and quality business decisions. If top management doesn’t expect more, accountants will remain a costly piece of overhead.

Every manufacturer needs a great financial business partner, not just to do the books and handle financial reporting, but to create effective information that allows all parts of the organization to focus on improving the business for greater profitability. For this, “Profitable Expectations” provides a practical and readable guide.

10/29/20 11:38 PM

42 IT VIEW

AW NOVEMBER 2020

T�e Connected Plant in the Digital World Sanjiv Kumar sanjiv.k@tcs.com Managing Partner— Tata Consultancy Services & MESA Member

T

here are multiple definitions of the connected plant on various forums from various organizations. The emphasis on a particular construct may change, but essentially, it’s always about real-time visibility, providing insights into plant operations, and at the highest level of maturity, providing predictive capability and autonomous operation.

This is possible through connectivity to assets, machines, and control systems, and by leveraging digital technologies such as Big Data, cloud, mobility, API-based integration, microservices, and artificial intelligence and machine learning algorithms.

These constructs take the shape of different applications like plant historians, OPC servers, digital Andon boards, daily work management, plant manager dashboards, Industrial Internet of Things platforms, analytics workbenches, and many others, all working in conjunction with advanced automation, autonomous vehicles, next-gen robots and collaborative robots, augmented and virtual reality equipment, digital twins, 3D printing, RFID, and a whole host of new Industry 4.0 technologies.

But before digging into the technology aspects, it’s important to harmonize and streamline business processes on the plant floor. The essential activities of production, quality, material flow, maintenance, and environmental health and safety have not changed, but these activities need to be aligned for the plant, and more importantly, to the overall vision of the organization.

This brings us to the aspect of having the right set of measures and key performance indicators (KPIs) in a consumable data product, such as a dashboard, to determine whether you are winning or if you need to make some course corrections.

2011_ITView.indd 42

The industry seems to be well aware of what a connected plant is and what the key constructs of its implementation are. The big question is why this should be done and how to move forward.

I’ve been talking to various manufacturing organizations about their challenges in initiating and realizing their connected plant objectives. Besides having the technical know-how to implement the systems of the connected plant, I have come to recommend three important activities to consider before embarking on this journey.

Business case and strategy

I think this is the biggest challenge manufacturing plants face in terms of adopting Industry 4.0 and realizing the vision of connected plants. The benefits are not straight forward, especially in the age of the COVID19 pandemic where many plants are running at limited capacity. It’s important to truly understand the impact of the connected plant within a single function as well as between multiple functions.

For example, insights from overall equipment effectiveness would help in focusing not only on the maintenance and quality functions, but also on the production planning and scheduling functions. The throughput improvement decision would have an impact on energy consumption as well. The biggest areas of improvement are yield, throughput, inventory, and the positive impact of avoiding breakdowns and major incidents. It’s important to lay out the business plan for your connected plants and include both qualitative and quantitative benefits.

Change management

The power of the connected plant systems gets unlocked when the systems, processes, and functions are connected in context. It’s beyond a specific work cell, assembly line, or any other production area. This requires a change in mindset and a cultural change on the shop floor. It requires a change in perspective from point systems to an integrated view, from local efficiency improvements to integrated plant floor scorecard improvements, and from efficiency and cost optimization to a transformation and growth focus. Develop a comprehensive track for change management as part of

your strategy which includes understanding the benefits and impacts of the connected operations and the ability to use the digital technology.

Product-centric organization approach

A lot of questions on the viability of Industry 4.0 concepts and technologies have now been addressed and each industry is adopting Industry 4.0 in its own way. As was mentioned in the beginning of this article, there are different applications which can be implemented but it’s important to have a game plan—a high-level vision of the end state and a paced plan—to build it block by block.

The product-centric organization approach is most appropriate where you define one or more products to meet your connected plant vision and objectives, and then build your applications based on the business case over a period of time. The concepts of agile development are very helpful in thinking big, but pace the deployment of different use cases over time. Be sure to carefully define the minimum viable product for each product and the development backlog for use cases.

These three activities included as part of your connected plant initiative will help provide management buy-in, employee adoption, and the realization of significant benefits.

T�e industry seems to be well aware of what a connected plant is and what the key constructs of its implementation are.

T�e big question is why this should be done and how to move forward.

10/29/20 11:38 PM

ADVERTISER INDEX 43 AW NOVEMBER 2020

Statement of Ownership, Management, and Circulation (Requester Publications Only) 1. Publication Title

2. Publication Number

Automation World

1 5 5 3

4. Issue Frequency

_

12

Sept 28 2020

1 2 2 4

5. Number of Issues Published Annually

Monthly

7. Complete Mailing Address of Known Office of Publication (Not printer) (Street, city, county, state, and

6. Annual Subscription Price (if any) Contact Person

ZIP+4 ®)

George Shurtleff

Telephone (Include area code)

312-205-7890

8. Complete Mailing Address of Headquarters or General Business Office of Publisher (Not printer)

PMMI Media Group, 401 North Michigan Ave., Suite 300, Chicago, IL 60601 9. Full Names and Complete Mailing Addresses of Publisher, Editor, and Managing Editor (Do not leave blank) Publisher (Name and complete mailing address)

Kurt Belisle, PMMI Media Group, 401 North Michigan Ave., Suite 300, Chicago, IL 60601 Editor (Name and complete mailing address)

David Greenfield, PMMI Media Group, 401 North Michigan Ave., Suite 300, Chicago, IL 60601 Managing Editor (Name and complete mailing address)

10. Owner (Do not leave blank. If the publication is owned by a corporation, give the name and address of the corporation immediately followed by the names and addresses of all stockholders owning or holding 1 percent or more of the total amount of stock. If not owned by a corporation, give the names and addresses of the individual owners. If owned by a partnership or other unincorporated firm, give its name and address as well as those of each individual owner. If the publication is published by a nonprofit organization, give its name and address.)

Complete Mailing Address Full Name

11911 Worldgate Drive, #200, Herndon VA 20170

PAGE

AutomationDirect

800.633.0405 www.automationdirect.com/GS20 Cover-2

Contemporary Controls 630.963.7070 www.ccontrols.com/ctrlink Digi-Key Electronics

800.344.4539 www.digikey.com/automation

Galco

888.526.0909 www.galco.com

19 3 Cover-3

Hammond Manufacturing

716.630.7030 www.hammondmfg.com

15

Helukabel

855-HELUUSA www.helukabel.com

31

Inductive Automation

800.266.0909 www.demo.ia.io/automation

5

800.526.9328 www.motionindustries.com

25

Motion Industries

800.526.9328 www.motionindustries.com

Cover-4

Pepperl + Fuchs

330.425.3555 www.pepperl-fuchs.com/smart-ex-02

37

800.435.2121 www.tesensors.com/XXSonic

13

Motion Industries

11. Known Bondholders, Mortgagees, and Other Security Holders Owning or Holding 1 Percent or More of Total Amount of Bonds, Mortgages, or Other Securities. If none, check box.

None Full Name

TELEPHONE WEBSITE

N/A

PMMI Media Group, 401 North Michigan Ave., Suite 300, Chicago, IL 60601

PMMI

COMPANY

3. Filing Date

Complete Mailing Address

(advertorial)

12. Tax Status (For completion by nonprofit organizations authorized to mail at nonprofit rates) (Check one) The purpose, function, and nonprofit status of this organization and the exempt status for federal income tax purposes: Has Not Changed During Preceding 12 Months Has Changed During Preceding 12 Months (Publisher must submit explanation of change with this statement.)

PS Form 3526-R, July 2014 [Page 1 of 4 (See instructions page 4)] PSN: 7530-09-000-8855

PRIVACY NOTICE: See our privacy policy on www.usps.com.

Telemecanique Sensors 13. Publication Title

14. Issue Date for Circulation Data Below

Automation World

September 2020

15. Extent and Nature of Circulation

Average No. Copies No. Copies of Single Each Issue During Issue Published Preceding 12 Months Nearest to Filing Date

52,159

a. Total Number of Copies (Net press run) Outside County Paid/Requested Mail Subscriptions stated on PS Form 3541.

(Include direct written request from recipient, telemarketing, and Internet (1) requests from recipient, paid subscriptions including nominal rate subscriptions, employer requests, advertiser’s proof copies, and exchange copies.) b. Legitimate Paid and/or In-County Paid/Requested Mail Subscriptions stated on PS Form 3541.

Requested (Include direct written request from recipient, telemarketing, and Internet Distribution (2) requests from recipient, paid subscriptions including nominal rate subscriptions, (By mail employer requests, advertiser’s proof copies, and exchange copies.) and outside Sales Through Dealers and Carriers, Street Vendors, Counter the mail) (3) Sales, and Other Paid or Requested Distribution Outside USPS® (4)

35,152

0

0

d. Nonrequested (2) Distribution (By mail and outside the mail) (3)

(4)

In-County Nonrequested Copies Stated on PS Form 3541 (include sample copies, requests over 3 years old, requests induced by a premium, bulk sales and requests including association requests, names obtained from business directories, lists, and other sources) Nonrequested Copies Distributed Through the USPS by Other Classes of Mail (e.g., First-Class Mail, nonrequestor copies mailed in excess of 10% limit mailed at Standard Mail ® or Package Services rates)

f.

Total Distribution (Sum of 15c and e)

g.

Copies not Distributed (See Instructions to Publishers #4, (page #3))

h.

Total (Sum of 15f and g)

i.

Percent Paid and/or Requested Circulation (15c divided by 15f times 100)

PS Form 3526-R, July 2014 (Page 2 of 4)

Automation World Magazine a. Requested and Paid Electronic Copies b. Total Requested and Paid Print Copies (Line 15c) + Requested/Paid Electronic Copies (Line 16a)

0

PI North America

480.483.2456 us.pro net.com/go-digital

7

Wago Corporation

800.DIN.RAIL www.wago.us/IIoT

3

0

15,682 50,834 178 51,012 69%

c. Total Requested Copy Distribution (Line 15f) + Requested/Paid Electronic Copies (Line 16a) d. Percent Paid and/or Requested Circulation (Both Print & Electronic Copies) (16b divided by 16c Í 100)

No. Copies of Single Issue Published Nearest to Filing Date

4,386 42,716 55,744 77%

3,827 38,979 54,661 71%

I certify that 50% of all my distributed copies (electronic and print) are legitimate requests or paid copies.

17. Publication of Statement of Ownership for a Requester Publication is required and will be printed in the issue of this publication.

18. Signature and Title of Editor, Publisher, Business Manager, or Owner

George Shurtleff PMMI Media Group Production Manager

November 2020 Date

9/25/2020

I certify that all information furnished on this form is true and complete. I understand that anyone who furnishes false or misleading information on this form or who omits material or information requested on the form may be subject to criminal sanctions (including fines and imprisonment) and/or civil sanctions (including civil penalties).

November20_AW_AdIndex.indd 43

Automation World IIoT November 2020

800.321.6786 www.opto22.com

0

Average No. Copies Each Issue During Previous 12 Months

7

Opto 22

Statement of Ownership, Management, and Circulation (Requester Publications Only)

16. Electronic Copy Circulation

800.DIN.RAIL www.wago.us/pfc200

0

0

* If you are claiming electronic copies, go to line 16 on page 3. If you are not claiming electronic copies, skip to line 17 on page 3.

Wago Corporation

800.99.FESTO www.festo.us

15,682

13,028 51,358 801 52,159 75%

1

Festo Corp.

35,152

12,828

200

Nonrequested Copies Distributed Outside the Mail (Include pickup stands, trade shows, showrooms, and other sources)

Total Nonrequested Distribution [Sum of 15d (1), (2), (3) and (4)]

0

38,330

Outside County Nonrequested Copies Stated on PS Form 3541 (include sample copies, requests over 3 years old, requests induced by a premium, bulk sales and requests including association requests, names obtained from business directories, lists, and other sources)

e.

18

0

940.565.8800 www.gonature.tetrapak.com

20

Requested Copies Distributed by Other Mail Classes Through the USPS (e.g., First-Class Mail®)

c. Total Paid and/or Requested Circulation (Sum of 15b (1), (2), (3), and (4))

(1)

51,012

38,310

Tetra Pak

9 12

Automation World ® (ISSN # 15531244, USPS 22435) is a registered trademark of PMMI, The Association for Packaging and Processing Technologies. Automation World ® is published 14x a year by PMMI with its publishing office, PMMI Media Group, located at 401 N. Michigan Avenue, Suite 300, Chicago, IL 60611; 312.222.1010; Fax: 312.222.1310. Periodicals postage paid at Chicago, IL, and additional mailing offices. Copyright 2020 by PMMI. All rights reserved.

Materials in this publication must not be reproduced in any form without written permission of the publisher. Applications for a free subscription may be made online at www.packworld.com/subscribe.

Paid subscription rates per year are $105 in the U.S., $147 Canada and Mexico by surface mail; $250 Europe, South America. $325 Far East and Australia by air mail. To subscribe or manage your subscription to Automation World, visit AutomationWorld.com/subscribe. Free digital edition available to qualified individuals outside the United States. POSTMASTER; Send address changes to Automation World®, 401 N. Michigan Avenue, Suite 300, Chicago, IL 60611. PRINTED IN USA

by Quad Graphics. The opinions expressed in articles are those of the authors and not necessarily those of PMMI. Comments, questions and letters to the editor are welcome and can be sent to: editors@automationworld.com. We make a portion of our mailing list available to reputable firms. If you would prefer that we don’t include your name, please write us at the Chicago, IL address. Volume 18, Number 11.

10/29/20 2:13 PM

44 KEY INSIGHTS AW NOVEMBER 2020

Virtualization is ideal for todayâ&#x20AC;&#x2122;s environment of digital transformation because we not only reduce the quantity of hardware we need to buy, but we also increase our agility and adaptability such that we can more easily respond to changing business requirements.

And virtualization allows us to do this without big rip-and-replace cycles and it reduces vendor lock in.

David Greenfield on understanding virtualization for industrial automation. http://awgo.to/1103

Though capturing images at a high-speed is often important in production operations, it is not the only function needed in a machine vision system; sometimes accuracy takes precedence.

Luis Rodriguez on new machine vision technologies. http://awgo.to/1104

If you have a human out there inspecting products, they are subject to change in a lot of it. What they think might be a defective piece of food one day, they might say is an OK piece of food the next day.

Aaron Hand on the use of artificial intelligence for food safety. http://awgo.to/1105

Factors contributing to manufacturersâ&#x20AC;&#x2122; difficulties in overcoming barriers to remote access technology use include regulating OEM/vendor capabilities, deploying cybersecurity to allow access only when needed and restricting access to unknown/suspect sites, and getting engineers and information technology to work together and leverage skillsets.

Pat Reynolds on the barriers to greater remote access technology use. http://awgo.to/1106

Having virtualized systems and mobile platforms allowed clients to make changes without needing to go to a piece of equipment. This was especially critical at a time when companies were simultaneously working to keep critical and regulated manufactured goods at normal production levels while working to implement contact tracing and COVID-19 operational plans.

Will Aja of Panacea Technologies on technological transitions during the pandemic. http://awgo.to/1107

2011_KeyInsights.indd 44

10/29/20 10:12 AM

REPAIR PARTS

LEVEL, PRESSURE & FLOW

ELECTRICAL

Full Page Ad.indd 73

10/29/20 11:08 AM

tim

Always

Hose and Reel Accessories

Motio I dust i s com

Full Page Ad.indd 73 Full Page Ad.indd 73

10/29/20 11:07 AM 8/24/20 10:54 AM