PACE Today - June/July 2017

JUNE/JULY 2017 | VOL.70 NO.3 | Est. 1953

JUNE/JULY 2017 | VOL.70 NO.3 | Est. 1953

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INSIDE PACE

Energy Management

Automation

Safety Systems

Failsafe power helping to eliminate blackouts

Why cobots are set to drive automation

How digital controllers can improve process safety

MORE IMPORTANT THAN EVER EXCLUSIVE: How embracing the IIoT can increase productivity

CONTENTS

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Managing Director: John Murphy Managing Editor: Syed Shah Editor: Mike Wheeler Ph: (02) 9439 7227 mike.wheeler@primecreative.com.au

Journalist: Stephanie Stefanovic Ph: (02) 9439 7227 stephanie.stefanovic@primecreative.com.au

IN THIS ISSUE 12

Sales/Advertising: Nick Baker Ph: (02) 9439 7227 nick.baker@primecreative.com.au Production Coordinator: Kristina Peric Ph: (02) 9439 7227 kristina.peric@primecreative.com.au Art Director: Michelle Weston Designer: James Finlay, Blake Storey, Adam Finlay SUBSCRIPTIONS: $99 pa incl GST NZ: $A109 pa & OS: $A119 pa Subscriptions: Gordon Watson Ph: (03) 9690 8766

30 News 8

Making processing more efficient New Technology 9

The Omron Robot

A new project opens up opportunity for Sydney company Safety 12

How digital controllers can improve process safety and efficiency Internet of Things 14

Strategic Implementation of IIoT in Refineries; It’s all about the connection: How IoT drives profitability and growth

© Copyright Prime Creative Media, 2017 Articles All articles submitted for publication become the property of the publisher. The Editor reserves the right to adjust any article to conform with the magazine format.

Head Office 11-15 Buckhurst St South Melbourne VIC 3205 P: +61 3 9690 8766 enquiries@primecreative.com.au www.primecreative.com.au

Panel PCs and Displays 18

A look at a new wide screen format Panel PC

Sydney Office Suite 303, 1-9 Chandos Street, Saint Leonards, NSW 2065, Australia

Automation 20

Why Cobots are set to drive automation Energy Management 24

Wastewater 10

Copyright PACE is owned by Prime Creative Media and published by John Murphy. All material in PACE is copyright and no part may be reproduced or copied in any form or by any means (graphic, electronic or mechanical including information and retrieval systems) without written permission of the publisher. The Editor welcomes contributions but reserves the right to accept or reject any material. While every effort has been made to ensure the accuracy of information, Prime Creative Media will not accept responsibility for errors or omissions or for any consequences arising from reliance on information published.

The opinions expressed in PACE are not necessarily the opinions of, or endorsed by the publisher unless otherwise stated.

28

Failsafe power helping to eliminate hospital blackouts Sensors 26

The challenges of sensing for oil and gas Standards 30

Putting ISO Standards into a real-world context Test and Measurement 32

How to improve parts management in mine sites

Level Measurement 34

How to effectively measure liquids from outside a vessel New Products 36

All the latest new products for the process and control industry ON THE COVER

Industry Safety

Average Net Distribution Period ending Sept ’15 5,521

JUNE/JULY 2017 | VOL.70 NO.3 | Est. 1953

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INSIDE PACE

Energy Management

Automation

Safety Systems

Failsafe power helping to eliminate blackouts

Why cobots are set to drive automation

How digital controllers can improve process safety

MORE IMPORTANT THAN EVER EXCLUSIVE: How embracing the IIoT can increase productivity

4 www.pacetoday.com.au JUNE/JULY 2017

In the past, Australian manufacturing has had a high rate of injuries – almost double the national average. Part of the problem is that manufacturers see safety issues as costing them with their bottom line. Also, it was found that safety culture was driven by legislative need to comply as opposed to doing so because it is the right thing

to do. What they need to do is take a big picture view. Having the correct safety procedures and protocols in place could have a more positive effect. If management and staff buy into a safety system, then that is half the battle won. And if everybody buys into it, then over time the cost savings will improve.

COMMENT

EDITOR’S MESSAGE

Mike Wheeler Editor

Automation – how far do we go?

A recent story caught my eye about a company in Sweden – Epicentre – that has asked its employees if they would like to be microchipped. Surprisingly, more than 150 of the company’s workers said ‘yes’ to the scheme.

While the microchips have been designed to do tasks like opening doors and other mundane chores, it does bring up the question of how far are we willing to go with automation. Where does it stop?

Will it monitor toilet breaks? Will it keep track of where you shop? What you buy? Do we risk becoming too

6 www.pacetoday.com.au JUNE/JULY 2017

automated? That got me thinking about automation and robotics in the workplace. A story on page 20 tells of how cobots, or collaborative robots, are starting to insert themselves into the manufacturing process, especially those tasks that are repetitive and boring to humans. Are we at risk of boring ourselves out of work? From a company’s perspective, automating these jobs makes sense – from cost and return of investment, through to safety issues. But what will be the cost further down the road?

For the past 18 months the

buzzword on industry lips has been the Industrial Internet of Things (IIoT), whereby internet-connected devices are being more and more integrated into the production process.

We have a couple of interesting stories starting on page 14 that look at how the IIoT can be adapted into various industries and the affect this will have on outcomes. Some believe that all these connected devices can help industries by offering greater insights into how to stream line production processes, which in theory should lead to higher productivity. A report by

Aruba Networks suggests that those who invest in the IIoT will get a return of investment of 34 per cent.

Aruba goes one step further and insists that being involved in the IIoT is not a choice, but a necessity.

On another note, International Standardisation Organisation (ISO) standards are in the firing line. Sort of. On the face of it, standards are something that every company should adhere to. The ISO is a highly regarded body that sets the standards for an array of industries that are designed to make various production processes uniform, as well as making sure safety criteria are met. However, SMC Pneumatics is one company that is asking the question “What if standards are holding us back?” They make for an interesting argument on Page 30.

Then there is the issue of having a reliable power supply in case of blackouts, or energy company-led brownouts. Most critical infrastructure – such as hospitals – have generators and alternative power supplies in place in case of critical failure. However, one aspect that needs to be taken into consideration is that the right type of equipment is in place to make sure the power switch over is safe and doesn’t cause problems. A story on Page 24 offers a safe solution to an issue that doesn’t compromise on safety.

Finally, on a personal note, I’m really excited to be part of an industry that is at the cutting edge of technology. I look forward to touching base with many of you over the next few months about some the new products, services and stories that you want to talk about. If there are any industry issues you think are important and need discussing email me at mike.wheeler@primecreative. com.au. PACE

NEWS

What will it take to make Australian processing operations more efficient?

PACE looks at how reinventing Australia’s manufacturing industry relies on how well we adapt to new technology.

A

ccording to the Boston Consulting Group’s Cost Competitive Index (CCI), Australia’s increasingly high-cost environment is harming processing operations within industry.

In fact, Australia has the highset manufacturing cost structure out of all the nations surveyed, at around 30 per cent higher than the US. Australia has fallen from the 19th to 25th most productive manufacturing industry over the past decade and much of this has been due to a massive drop in productivity in the country over the past 10 years.

A study by consultancy firm McKinsey showed that multi-factor productivity was growing up until 2005; but it dropped 0.7 per cent per year until 2011, when the study was carried out.

Late last year IBM, as part of its Smarter Planet initiative, signalled that the industry is starting to top off with regard to productivity and must innovate.

“This, right now, is the tipping point we believe, where the risk of inaction outweighs the risk of action,” said Andrew Stevens, managing director of IBM Australia and New Zealand.

The Reinventing Australian Enterprises for the Digital Economy report considered what the year 2025 might look like for manufacturers operating in a range of industries.

It found that the future relied on how well they adapted to new technology and used it to “deliver unique value to customers and citizens with the speed, efficiency and ubiquity they demand”.

According to Manufacturing Australia’s Ben Eade there is a way 8 www.pacetoday.com.au JUNE/JULY 2017

for the industry to overcome these problems, and that is by focusing on more efficient and productive methods such as automation and better manufacturing processes. Australia needed to follow Switzerland’s lead, which has high costs but also high productivity, Eade explained.

Process automation and machinery

refurbishment are two major ways that manufacturers are forecasting to address the underlying issues affecting Australia’s competiveness and highcost operational structure.

New technologies can also be incorporated within the refurbishment that further improve the situation for the industry.

According to Australian company Sentient Automation “ignoring the productivity improvements that can be made by machine and process upgrades means that as production requirements change the process will continually drift away from the ideal, and profitability will suffer.” PACE

NEW TECHNOLOGY

Industrial mobile robot with high payload capacity Omron has released its first industrial mobile robot with a self-navigation system.

M

obile robots provide a new level of efficiency and cost savings when it comes to moving goods around large facilities. Omron has recently introduced its first mobile robot product line, the LD platform.

This family of robots was developed for rapid, reliable materials transport 24/7, and can self-navigate in even the most dynamic environments.

Suitable for conveying goods throughout warehouses, distribution centres and manufacturing facilities, the LD mobile robot platform has a payload capacity up to 130kg, depending on the model. The robots

can self-navigate entirely based on the natural features of the facility.

No costly and time consuming infrastructure modifications are necessary, so there is no need for floor magnets, tapes or laser beacons typically associated with classic automated guided vehicle (AGV) deployment. Flexible factory layout can be achieved as delivery points can be modified for the mobile robots. Omron mobile robots also complement traditional automation, such as conveyors, and provide traceable movement of goods.

Equipped with Acuity technology, these robots have a robust self-

navigation system even where there is constant movement of people, pallets, carts and forklifts, or when shelves are being emptied and restocked.

They are equipped with on-board intelligence to avoid obstacles and choose the best path to complete a task. This intelligent movement also makes them safe to operate alongside people as collaborative machines. Up to 100 vehicles can form a fleet and be centrally managed by a fleet manager, which can interact with the factory or warehouse management software such as MES. In addition to the LD OEM series, which is designed for an end

user or system integrator to add application-specific payloads, also available is LD Cart Transporter, which is an automated material handling solution designed to move carts. The Cart Transporter includes an automatic engagement device and is able to adjust its approach path to automatically engage the cart.

This makes the Cart Transporter a suitable solution to provide line-side replenishment for assembly line or for e-commerce order fulfilment in a distribution centre. PACE Omron Industrial Automation Australia 1300 766 766 www.omron.com.au

Omron mobile robots also complement traditional automation, such as conveyors.

JUNE/JULY 2017 www.pacetoday.com.au 9

WASTEWATER

High screen capture rate in wastewater treatment plant Headworks equipment supplier, Aqseptence, has won a contract on a Sydney wastewater project that will support more than half a million residents in the city’s western suburbs.

A

qseptence Group has won a contract to supply fluid filtration and separation equipment for Sydney Water’s Lower South Creek Program.

The Lower South Creek Program will construct three new treatment plant upgrades at Riverstone, Quakers Hill and St Marys, and is set to cost $300 million. It will support an additional 500,000 people in western Sydney by 2040. It is a joint venture between Sydney Water, Parsons Brinckerhoff and UGL. Supplied equipment will include Aqseptence Group’s Centre-Flo with honeycomb panel, which has greater than 30 per cent

improved hydraulic capacity and 5 per cent greater screen capture rate – based on 5mm apertures – over a conventional perforated plate screen panel. The improved hydraulic capacity allows existing inlet works to increase hydraulic throughput without civil modifications while providing cost savings for new sites through smaller mechanical and civil footprints.

“Aqseptence Group has been working very hard to develop the latest patented honeycomb screen panel to integrate into our band screen,” said Aqseptence Group’s ANZ Sales Manager Chris Susanto.

“We are pleased to have Sydney Water, one of Australia’s largest water utilities, acknowledge and accept the use of the innovative new technology.

We are looking forward to continuing our relationship with Sydney Water throughout the Lower South Creek Program as well as future works.”

“The recent contract for the Lower South Creek Program with ADAPT reflects our status as the leading headworks equipment supplier in the Australian Water Industry,” said Aqseptence Group’s Managing Director David Lazzarini. “[Our] commitment to product research and development continues to position us to offer

our clients world-leading innovative technology. To have our latest fluid filtration and separation innovation selected for such an important project is reward for a lot of hard work by our engineers.’’

The initial Riverstone STP package for the Lower South Creek Program will include three Aqseptence Group honeycomb panel Centre-Flo band screens, two Noggerath Nogwash screw wash presses, manual bar screens, vortex grit tank, grit classifier and associated pumps and launders. PACE Aqseptence www.aqseptence.com 07 3867 5551

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DRIVING YOUR INDUSTRY 4WARD.

Industrial automation is changing at an extremely rapid pace. As an innovation leader, developing cutting-edge sensor technology, SICK offers solutions today that are ready for the challenges of the future. With intelligent sensors that collect data, evaluate them in real time, adapt to their environment and communicate in the network. Enabling a new quality of flexibility and networked intelligence for efficient processes and reliable cooperation of humans and machines. We think that’s intelligent. For more information please visit www.sick.com.au or call 1800 334 802.

SAFETY

How an autonomous approach to safety can boost productivity A white paper by SICK argues manufacturers need to move away from thinking of safety as a cost burden.

Instead they should think that it is a way that can save them money in the long run.

Using current safety automation technologies makes the adoption of new safety standards simple.

F

rom 2010-2011, Australia’s manufacturing industry experienced the third highest injury incidence rate of all industries, with rates almost double that of the national average.

When taking into consideration the increasing autonomy of manufacturing processes, it’s a bitter pill to swallow; and yet still today almost 95 per cent of all workplace accidents occur as a result of human error. For responsible manufacturers who regard safety as a number one workplace priority, results like this can prove hugely discouraging.

While investment in workplace safety is often seen as a bottom-line burden, many forward-thinking 12 www.pacetoday.com.au JUNE/JULY 2017

businesses have come to regard safety assurance as a crucial lever for enhancing operational performance and productivity.

Rather than relegating safety procedures to series of punitive actions, modern safety assurance represents a key opportunity for manufacturers to gain a competitive edge. Evidence shows that a proactive approach to safety not only protects workers from serious injury and boosts workplace morale, but greatly reduces the chance of business-crippling machine downtime.

For today’s Best-in-Class manufacturers, a well-balanced combination of advanced safety technologies, adherence to global safety

standards, and a positive shift in the workplace safety culture have proved a powerful means to mitigate workplace hazards and add real financial value to the business.

There is a common misconception that safety and productivity are opposing interests. This idea is formed from ill-designed safety methodologies that continue to embrace legacy technologies and outmoded management approaches.

Up until the 1990s, these attitudes were grounded in practical reality.

The mission-critical nature of factorylevel infrastructure, and the general lack of confidence in – and regulation of – microprocessor systems, meant that early microprocessor-based

safety control systems were generally disfavoured as an industry technology.

These “traditional” safety systems were typically hard-wired, relay-based systems, operating independently to guarantee the highest possible availability: this ensured that a failure in “normal” operations would not compromise or degrade the overall safety process.

One of the fundamental drawbacks of this ‘siloed’ approach is that the safety system, by default, had a lower level of “intelligence” capability than the machine control system. This discrepancy imposed serious limitations on the integration capabilities between the two systems.

The introduction of industry

SAFETY

“When taking into consideration the increasing autonomy of manufacturing processes, it’s a bitter pill to swallow; and yet still today almost 95 per cent of all workplace accidents occur as a result of human error.” standards in the late 1990s, particularly IEC 61508, paved the way for microprocessor-based controllers for manufacturing safety systems. This in turn supported greater integration between the machine control and safety control systems, leading to improved diagnostic capabilities and cooperation between control systems.

The benefits of adopting newer safety control technologies include the flexibility provided by software configurable/programmable devices.

This means that the inevitable changes to production techniques, processes or materials, requiring revision of the safety control system, are more easily addressed.

Using current safety automation technologies makes the adoption of new safety standards – with the benefits they bring – a much simpler process.

What’s more, the costs of maintaining legacy technologies can grossly outweigh the expense of upgrading. This includes the increasingly high costs of labour and, in the event of a safety related stoppage, troubleshooting and production downtime.

Evidence shows that manufacturers who invest in integrated safety technologies will not only reduce manufacturing risks and streamline standards compliance, but will improve workplace productivity. Despite the advantages of an integrated approach, these legacy safety systems still dominate the manufacturing landscape.

A 2010 Aberdeen Group study into industrial safety and productivity found that safety culture in manufacturing is still largely driven by pressure to comply with regulatory standards. While today’s

Upgrading safety systems is an investment requiring specialised industry and equipment knowledge.

‘Best-in-Class’ companies recognise a corporate duty to deliver a safe working environment, many businesses maintain a retroactive attitude to compliance, acting only when commercially expedient. The potential fallout from noncompliance, however, extends far beyond concerns over brand equity, with the imposition of costly penalties, plant shutdowns and the potential for serious worker injury.

Simply acknowledging recognised safety standards isn’t enough to guarantee ground level compliance.

Without a supportive management team, poor safety habits and ill-discipline can proliferate, shattering staff morale and creating workplace cultures where avoidance is a cure and critical safety hazards go unreported.

As evidenced from Alcoa’s bold safety shake-up in the 1990s, simple strategies can go a long way to improving injury incidence figures and, as a result, worker productivity.

Enacting positive procedural changes, such as ‘no-guilt’ hazard reporting and regular fostered engagement between ground staff and management, can help transform any business from safety liability into a productive powerhouse.

In terms of financial cost, the

high failure rate of outmoded safety technologies and methodologies can prove a crippling business expense — industry estimates calculate that the average manufacturing downtime event can hit an astronomical AU$2.1 million per hour. Financial pressures like this can defeat the value of any safety program, as workers who are pushed to meet deadlines or efficiency targets can forgo safety when needed most. Such practices are rife throughout today’s manufacturing industry.

Companies who are proactive with regulatory changes (including ISO 61800-1), who evolve with new technology and implement proper safety control systems, will be able to enjoy high level production and reap the benefits from reduced downtime and injury risk.

Deciding to upgrade safety systems is an investment requiring specialised industry and equipment knowledge.

This ensures that every decision is made in line with current Australian and global legal requirements, and in full accordance with your production needs, safety systems, and corporate responsibilities.

SICK is a technology leader in industrial safety systems, offering scalable safety solutions for many applications, ranging from wash down environments in food and beverage manufacturing, to challenging environments within the timber and cold storage industries. The company offers trendsetting products and application-oriented functionality in everything from simple machine guard door interlocks to intelligent safety light curtains, cameras, laser scanners and programmable safety controllers with motion monitoring capabilities.

SICK’s offering is complemented by a holistic ‘Safety Plus’ philosophy, combining experience, competence, and high technology with full system openness and a comprehensive suite of safety services.

According to SICK its safety solutions enhance your investment, achieve greater potential for savings through more efficient processes, and always focus on the primary goal – human and machine safety. PACE SICK Australia 1800 334 802 www.sick.com/au JUNE/JULY 2017 www.pacetoday.com.au 13

INTERNET OF THINGS

Strategic implementation of the IIoT in refineries New technology is where the oil and gas industries are heading and it’s important for refinery managers to be aware of this, writes Glenn Fermoyle, National Business Development Manager, Software, Global Solutions, Schneider Electric.

T

he Industrial Internet of Things (IIoT) has enabled unprecedented connectivity, communication and the transfer of data, giving managers the best opportunity to access real-time data and make informed decisions.

As the cost of connectivity and data storage fall, a variety of processes across the entirety of the oil and gas chain have the ability to collate and gain more data from even more devices, assets, processes and operations than ever before.

However, with the wealth of data available at our finger tips, refineries are still struggling to use this efficiently. There are a couple of reasons behind this.

In the current refinery landscape, the architecture which enables IIoT includes mature products and services.

Although these technologies have years of success and a good reputation, relying on these established products and services becomes a significant challenge for managers.

On top of this, we are facing a substantial change in the make-up of the industry’s workforce. It’s estimated that 50 per cent of all refinery staff will retire in the next five to seven years, making the millennial generation the largest generation in the workforce by 2025.

This poses a challenge in itself.

As we move to a workplace comprised of 20 year olds, who have significant technology experience yet lack industry knowledge, there is a significant information gap which needs to be filled. Hence this is a timely, pressing issue that will only become more significant in time.

With a noteworthy generational change, it’s of high priority that digital tools are used to capture the experienced generation’s knowledge, 14 www.pacetoday.com.au JUNE/JULY 2017

while delivering it in a way that resonates with the younger audience.

This is an important step that must be seriously considered in order to ensure the next generation of engineers stay up to date and ahead of the game.

Also, these digital natives can adapt to new technologies, quickly and easily, furthering the emphasis on keeping current in the industry.

The challenge today is to plan for tomorrow

Refineries can be described as industrial installations that are drowning in data but starving for insight. Although the existing technologies are providing us with a large amount of data, we are struggling to use this and implement changes based on insight into our work.

But by acknowledging that we currently have access to such data, it gives us the opportunity to leverage the information to an actionable intelligence and in a timely manner using new technologies. By realigning both existing investments and new technological advances, albeit challenging, greater insight and higher overall productivity will result.

Nevertheless, there are still some major areas that have been identified as gaps within the transition to an IoT-centric architecture. As one of the biggest risks with the IoT adoption, security poses a threat to transitioning infrastructures as this opens up a gap of vulnerability, until the full implementation of the system has been completed.

With any IoT adoption, security risk continues to be a barrier. Fear of the unknown with new technologies makes managers hesitant to adopt new technologies, with extra training and time consuming changes impacting on businesses bottom line.

“Fear of the unknown with new technologies makes managers hesitant to adopt new solutions, with extra training and time-consuming changes impacting on a business’s bottom line. ” Additionally, the lifecycle management and governance of the system involves integrating 15 application areas from multiple vendors. Therefore, the IoT strategy also requires the reduction of lifecycle costs in adapting and maintaining this large IT footprint.

Where to next for petroleum refiners?

For their part, Schneider Electric has developed a framework which assists in maximising the business value from the integration of the IoT. The foundation of this operational perspective starts

with the basic principle of the closed loop process.

The four stages of Schneider Electric’s framework can be applied narrowly (to a specific IoT use case), or broadly (to define a platform strategy) to guide the architecture of an integrated refinery information management system that enables connecting devices, collection and analysing data and closing the loop with actions that deliver operational benefits. PACE

Refineries are industrial installations that are drowning in data but starving for insight.

Schneider Electric Australia 1300 369 323 www.schneider-electric.com.au

NOMINATIONS NOW OPEN FOR 2017 2017

For more information and to nominate visit www.paceawards.com.au

INTERNET OF THINGS

How the IoT drives profitability and growth PACE spoke to Anthony Smith, General Manager, South Pacific, Aruba Networks about its recent report how the Internet of Things is going to impact on businesses — from healthcare through to manufacturing — and why it is important that industries come on board sooner rather than later.

A

s it stands, around 10 billion devices are currently connected to the Internet out of a potential 1.5 trillion that could connect. It’s also predicted that by 2020, around 50 billion devices will be connected. Think about that for a second. That’s only three years away, and the number of internet-connected smart devices will have increased by a factor of five.

According to Anthony Smith, general manager of Internet of Things (IoT) specialist Aruba, by 2019 up to 92 per cent of industrial organisations in the world will have adopted IoT technology and 77 per cent believe 16 www.pacetoday.com.au JUNE/JULY 2017

it will transform industrial and manufacturing.

“The top three sectors globally that indicated they are actively using IoT within the report were; IT, technology and telecoms (72 per cent), Industrial (62 per cent) and Healthcare (60 per cent),” said Smith. “However, these sectors also identified that whilst they are are actively using IoT, they are doing so with or without an IoT strategy in place.”

The impact of IoT

According to Aruba’s The Internet of Things: Today and Tomorrow report, 26 per cent of Australian businesses

already estimate around 20 to 30 per cent of devices on their networks are IoT enabled. So what are they doing with these devices?

“The top five industry adopters of IoT are enterprise, industrial and manufacturing, healthcare, retail and government. Drilling down into how the industrial and manufacturing sector is using IoT, we find that six in 10 businesses have already adopted IoT. They’re primarily using it for monitoring and maintenance of devices such as switches, pumps and other heavy plant and machinery,” said Smith.

“Using IoT, industry and

manufacturing can enable pieces of capital equipment to report its own status back to base. Potential faults are flagged before they become problems, and maintenance can be assigned before a fault becomes a serious issue.”

“Power consumption, uptime and mean time between services can also be monitored, and the data used to analyse past and present performance, and to predict future performance,” Smith said.

One in two businesses in the sector that have implemented IoT are using the data generated for improved business processes and decisionmaking. Additionally, 83 per cent

INTERNET OF THINGS

Helping to put you in Control

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Programmable Process Indicator report improved business efficiency, while a further 80 per cent have found improved visibility across the organisation.

“This means that there’s plenty of headroom for organisations, particularly in the industrial and manufacturing sector, to improve the way they use and analyse IoT data to improve business decision making,’ he noted.

Security remains an issue

Although the upsides to IoT deployment are significant, caution remains. As many Australian organisations have found to their peril, any device connected to the internet must be properly protected.

Something not all businesses take seriously, but need to if they are to keep themselves free from hackers.

“Many IoT devices by their very nature lack inbuilt complex security measures,” said Smith.

“Conventional IoT security methodologies need to be supported and secured by a robust and reliable network that allows organisations to apply policy management, automated device onboarding, device health checks, and scalable AAA for the strongest possible security,” Smith said.

“Security starts with understanding what’s on the network, what devices are being used, how many, and which operating systems are supported. Utilising a built-in profiling engine that collects real-time data, including device categories, vendors, and OS versions and provides visibility for those not ready for full policy enforcement, is key.”

Getting back to the report, 90 per cent of local businesses using IoT reported a security breach. That statistic is the highest in the world, and is bolstered by the fact only one quarter of businesses felt their cyber security infrastructure and security teams are fully prepared to support the IoT. Among other factors, the report also found that among those businesses yet to fully deploy IoT, 43 per cent of IT managers cite security as a key barrier that prevents their organisation from creating new IoT-related business value.

“Organisations need to ensure they have the best security-focussed features that are embedded in their corporate software to help prevent hacking and cyber threats, such as the benefits of two factor authentication and HTML5 for web-based business apps,” Smith said.

Where the value lies

When it comes down to it, IoT isn’t really about the devices. For all the switches, pumps and machinery that are connected to the Internet, the real value comes from the data generated by those devices.

Put simply, the IoT is all about capturing and analysing data and then turning that data into valuable insights to enable better-informed decision-

“Put simply, the IoT is all about capturing and analysing data and then turning that data into valuable insights to enable better-informed decision-making.” making. This feeds into the narrative many organisations are having around big data and digital transformation. At present, business already generates huge amounts of data. Add in millions of connected devices all generating their own data sets, and the amount of data becomes intimidating for even the most accomplished data scientist.

“In fact, some 53 per cent of IoT-enabled organisations cite managing large volumes of data as their biggest hurdle to fully using IoT,” said Smith.

“A further 44 per cent stated real-time data ingestion from multiple distributed devices as their main obstacle to maximising the business value of IT. “Creating value from the IoT therefore means that organisations must have big data analytic capabilities, either in house or from a trusted third party, if they’re going to make the most of their IoT-enabled infrastructure.

“This is underscored by the fact 29 per cent of organisations with an IoT implementation do not yet use the insights to improve their business processes, even though they analysed the data.

“Analysis and implementation of data-driven insights therefore remains the greatest challenge associated with the IoT, and it will pay any organisation looking to invest in the IoT to also have parallel investments in big data analytic capabilities.”

IoT is a rapidly growing area, and one that will touch virtually every business. Despite the hurdles, businesses that have invested in IoT are already reporting solid results from their rollouts. Of the businesses surveyed, most reported that their return on investment was 10 per cent greater than they had anticipated.

In line with this, Smith said that globally, the return on investment from IoT is reported at around 34 per cent.

“Clearly, there are good business reasons to invest in IoT. Generating data used for insights to improve business processes is but one,” said Smith.

“These can then be used to drive profits and competitive advantage over those businesses that have yet to fully implement an IoT and accompanying analytics strategy.” PACE Aruba Networks www.arubanetworks.com/en-au/

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Differential Temperature Controller with RS-485 Designed for solar water heating applications, the N321S comes with two NTC-type temperature sensor inputs and one control output and RS485 (Modbus RTU).

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For Wholesale prices Contact Ocean Controls Ph: (03) 9782 5882 oceancontrols.com.au Prices are subjected to change without notice.

JUNE/JULY 2017 www.pacetoday.com.au 17

PANEL PCS AND DISPLAYS

Rugged panel widescreen PCs for easy maintenance B&R has expanded its range of automation-ready Panel PCs with a new series of widescreen formats ranging from 7-inch WVGA to 24-inch Full HD. These Panel PCs are suited for use in harsh environments and are suitable visualisation devices for Box PCs, while at the same time offering easy and flexible mounting options.

B

&R’s Panel PCs combine a display and a PC into a single extremely compact device and are available in a wide variety of display sizes with a single-touch or multi-touch screen and/or input keys.

These Panel PCs are suited for use in harsh environments and are suitable visualisation devices for Box PCs, while at the same time offering easy and flexible mounting options.

With a slender design, all models are available with a single-touch or multi-touch screen. Connecting the panels to a PC unit turns them into a full-fledged PC, complete with scalable processing power.

The core component of the panel is the widescreen, which ranges from 7” WVGA to 24” Full HD, while the panels also have the possibility 18 www.pacetoday.com.au JUNE/JULY 2017

of adding a modular SDL/DVI receiver that turns the panels into operator terminals.

With SDL3 digital signal transmission technology with standard Ethernet cables, it is even possible for the panels to bridge more than 100 metres between terminal and PC. The Panel PCs offer scalable computing power by using anything from Intel Atom processors all the way up to the powerful Core i7 family.

The modular platform – consisting of the actual panel, SDL/SDL3 receiver and PC unit – is designed to deliver a reduction in maintenance costs, and in the event of an upgrade, there is no need to replace the entire Panel PC. Added to this, with its uniform

“The modular platform – consisting of the actual panel, SDL/SDL3 receiver and PC unit – is designed to deliver a considerable reduction in maintenance costs, and in the event of an upgrade, there is no need to replace the entire Panel PC. ” interface, B&R has established a flexible system platform for any future and expanded PC architectures.

Since the display and PC components are separate, it is also possible to upgrade the internal PC technology while at the same time keeping the original display unit.

Automation panels from B&R are built to meet exacting industrial

customers’ demands for maximum robustness, reliability and long-term availability. This is because the total cost over a product’s life cycle is what matters and where the cost advantages of B&R Panel PCs really come to the fore. PACE Daanet 1300 DAANET www.daanet.com.au

Bosch Australia Manufacturing Your partner in Automation & Robotics

Bosch Australia Manufacturing Solutions. Your partner in automation & robotics

INDUSTRY SECTORS t "(3*$6-563"- t 1)"3."$&65*$"- t "650.05*7& t .&%*$"- t .*/*/( t ."/6'"$563*/( t &/&3(: The team at Bosch use a cross functional approach to identify current manufacturing issues and work with the teams on site to develop solutions based on the needs of the business. I have been impressed by the ability of the Bosch team to engage our production staff to open up about current manufacturing issues and ensure their suggestions and proposals are explored and assessed.

APAS assistant collaborative robot

Shay Wilkinson TheTeam APASLeader assistant is a versatile automatic production assistant. As an intelligent and intrinsically – Process Engineering safe robot system, the APAS assistant allows direct collaboration with people without expensive Cook Medical

additional shielding. This is made possible by the unique sensor skin, which covers the robot arm of the APAS assistant and which reacts, as soon as somebody approaches.

Bosch Australia Manufacturing Solutions is uniquely positioned to deliver you bottom line results from efficiency and productivity gains achieved through the deployment of robotics and automation solutions. Our teams of industry experts specialise in designing, developing and deploying With a breadth of industries and products that extend from the automotive industry, to medical, pharmaceutical, healthcare, food, energy, power bespoke solutions that are tailored to the individual needs of our industry partners. tools, household appliances and whitegoods. With a strong history in supplying equipment to the automotive supply chain, Bosch Manufacturing Automation Lines,of Assembly Equipment, Material Handling, Axis / Robotics / Jigs & Fixtures Solutions now delivers into aAssembly diverse range Industries.

Test and Measurement Product Test Systems, Communication Interfaces, Data Analysis & Data Acquisitions Automation Assembly Line, Assembly Equipment, Material Handling, Axis /Robotics & Jigs & Fixtures Process Technology Dispensing Systems, Riveting, Tightening Systems, & Vision Systems Test & Measurement Product Test Systems, Communication Interfaces, Data Analysis & Data Acquisition Engineering Services Feasibility Studies, Lean Equipment Design, Project Management, System Integration Process Technology Dispensing Systems, Riveting, Tightening Systems & Vision Systems Call one ofServices our industry experts today to discuss how we can help Project you to achieve greaterSystem production efficiencies and bottom line results.

Engineering Feasibility studies, Lean equipment design, Management, Integrators Industry Expert: John Croft The standardized production assistants APAS assistant, APAS inspector and APAS flexpress, as a stand-alone solution or in a manufacturing island, M (61) (0) 434 185 329 are designed for: ad-hoc small series production, semi-automation, pilot production for safeguarding a process, agile engineering with early interim T (03)9541 5086 results and quality tests.

E john.croft@au.bosch.com To W findbosch-manufacturingsolutions.com.au out more contact John Croft M (61) (0) 434 185 329 T (03)9541 5086

AUTOMATION

Why Cobots are set to drive the automation revolution A recent survey of Australian manufacturers by Universal Robots indicates a growing emphasis on automation, particularly robotics, and especially the new breed of cobots, writes Shermine Gotfredsen, General Manager SEA & Oceania and Universal Robots.

A

ustralia’s manufacturing industry has been going through a period of significant change over the past decade as the sector faces increasing global competition, industrial reform and mass automation on an international scale. Almost half of Australia’s manufacturers have invested in automation in the past year.

Meanwhile, a majority of manufacturers say they plan to invest in automation in the coming year, with more than half of those respondents planning to install robotics solutions, making robotics the preferred automation option for Australian manufacturers.

This growth in automation investment has arguably been driven by an increased emphasis on business innovation. Australian manufacturers are challenged with high local labour costs, so increasingly they are looking for innovative ways to drive efficiencies and keep expenditures down.

Why automate?

The decision to automate is typically based on a number of crucial factors, namely the need to improve business performance, reduce production time and improve the quantity and quality of output.

New generation robotic solutions such as collaborative robots, or cobots, can provide greater ease of use and are able to work closely alongside human workers unlike traditional robotic solutions. This means shop floor applications can be quickly adapted to suit changing workflow needs.

When considering options, it’s important to think about future needs.

Organisations should look for solutions 20 www.pacetoday.com.au JUNE/JULY 2017

that will create efficiencies and grow their business. Automation is about integrating new technologies that will support and work alongside staff rather than reducing labour.

Today’s factories are highly agile in order to adapt to changing market demands. With the use of cobots, companies are able to adapt to the demands and whims of the market.

That is, they are able to decrease or increase product cycle times to suit consumer demand.

Unlike legacy industrial automation working behind cages, cobots can be quickly and easily assigned to new work stations and tasks based on changing

production needs, helping to reduce costs related to downtime.

For example, UR cobots can be reprogrammed and deployed for other tasks in a matter of minutes.

Considering safety

Cobots can be deployed to operate hazardous, monotonous and repetitive processes so that employees can be moved onto higher value tasks. By redistributing employees away from hazardous environments on the process line, the chances of injury through industrial accidents is reduced.

However, cobots also have certified safety measures allowing them to work

alongside workers safely in instances where it is important for humanmachine collaboration.

Most traditional industrial robotics require safety fencing, which can increase costs and take up a lot of space and create inflexible manufacturing processes.

Unlike traditional industrial machinery, cobots don’t require safety fencing (subject to a risk assessment).

In these situations, safety features such as sensors to detect an opposing force or obstruction in the robot’s field of operations ensure that cobots function safely and efficiently without causing harm to humans.

AUTOMATION

XT TION E N RA E EN

G

“New generation robotic solutions such as collaborative robots, or cobots, can provide greater ease of use and are able to work closely alongside human workers unlike traditional robotic solutions.”

Product quality

Before choosing an automation solution, it’s important to consider product quality and assurance, particularly if you’re planning to involve robots with tasks involving product assembly.

Cobots are said to offer high levels of quality control, which is particularly important for food manufacturers. The new lightweight industrial robots can operate within an error margin of plus-minus 0.1mm, which reduces the time employees need to spend on manual quality checks and prevents the wastage of food or packaging, for example.

One of the most important areas that many manufacturers should consider when deciding to implement an automation solution is whether it can achieve a calculable return on investment via substantial increase in productivity and efficiency.

Cobots are economical. They can generally be paid back within 12-months post-purchase, which means that companies can then reinvest in further product development and innovation. As manufacturing processes evolve to become smarter and more connected, less agile competitors must find a way to adapt.

Manufacturers must realise that smart factories offer not only the potential to improve operational efficiency but also greater agility and flexibility to adapt to meet changing markets demands. PACE Scott Automation + Robotics 02 9748 7001 www.scottautomation.com

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Ph: 1300 723 334 Ph: 03 9560 0621 Fax: 03 9574 9035 www.pilz.com.au safety@pilz.com.au JUNE/JULY 2017 www.pacetoday.com.au 21

THE GLOBAL LOGISTICS REVOLUTION MAY 10-12 2018 MELBOURNE CONVENTION & EXHIBITION CENTRE

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ENERGY MANAGMENT

Failsafe power helping to eliminate hospital blackouts In hospitals, you want to be able to rely 100 per cent on a stable, failsafe power supply. PACE talks to Pilz Australia’s managing director Scott Moffat about the hazards people and infrastructure face when switching between individual power supplies.

W

hether in operating theatres or looking after patients in intensive care wards, a reliable power supply is essential for a modern hospital. If the power and therefore the medical life support equipment should fail during a surgical procedure, the consequences would be unimaginable.

That’s why energy supply systems in hospitals are doubly or even triply protected via emergency generators and battery buffers. Ultimately you want to leave nothing to chance in this situation.

Switchover must be fast and safe

Whether willingly or out of necessity, situations do arise where users need to switch back and forth between individual power supplies. For technical reasons, it’s not simply a case of flicking a switch and then all systems continuing to work as before.

The contactors and shunt releases installed in the network must be in a defined state when the switch is made.

If not the system may break down, with resulting consequences for the expensive switchgear.

Depending on the situation, people in the immediate vicinity may also be put at risk.

A couple of years ago, White Technics was awarded a challenging contract by a hospital operator in a northern suburb of Melbourne.

White Technics had a wide range of experience in the planning and implementation of complex supply and energy technology installations.

“The task we were set was to develop a simple, reliable solution, 24 www.pacetoday.com.au JUNE/JULY 2017

which would bring the alternative power generator online quickly and safely, whenever a changeover was required,” said Pilz Australia’s managing director Scott Moffat.

Two independent substations supply power to this particular hospital. If these are unavailable, a diesel generator steps in.

If the power supply is shut down by the hospital during maintenance work or by the electricity supplier (a so-called brownout) the necessary switching arrangements can be made without any time pressure.

In contrast, in the event of an unforeseeable power outage (also known as a blackout), the second substation or generator must come online immediately and seamlessly, without even a momentary failure of the hospital’s critical systems.

Ensuring a safe switching process

For a redundant energy supply system to come online safely, a reliable entity must poll the status of the installed contactors and shunt releases within the shortest time possible.

The same applies if the reason for the shutdown (brownout or blackout) has been found and rectified: before being reset to the original power source, safe signals must be polled again and the current flow aligned synchronously to each power source.

“As we were already familiar with Pilz and its competence in integrated solutions for control and safety tasks, we decided to turn to the safe automation experts from Pilz Australia with this challenge,” said Moffat.

Both companies developed an efficient safety concept based on the

If the power should fail during a surgical procedure, the consequences would be unimaginable.

automation system PSS 4000. From a central control room, the system was intended to be able to communicate with the substation of the respective power grid, as well as with the generator.

As part of the automation system PSS 4000, the control system PSSuniversal monitors status inputs from each shunt release and contactor on the substations of the individual power grids.

Safety relays PNOZsigma from

Pilz control the circuit breakers via contactors. The automation system PSS 4000 also sends this information to the engineering office for diagnostic purposes.

Transfer by fibre-optic cable via SafetyNET from Pilz As the substations and the control room are around 800 metres apart, the connection between the control level and the remote I/Os in the field was implemented via fibre-optic

ENERGY MANAGMENT

cable and the real-time Ethernet SafetyNET p from Pilz.

“The ability to use the safe Ethernet protocol SafetyNET p via fibre-optic cable was an important prerequisite for our project,” said Frank White from White Technics.

SafetyNET p networks all the control components and transfers data for safety-related and non safety-related control tasks in one system.

With the software platform PAS4000, the Program Editor PASmulti and EN/IEC 61131-3 Editors, the automation system is easy and flexible to manage. The hospital’s maintenance team receives detailed diagnostics in the control room, without having to enter any high voltage areas. As a result, technical problems can be resolved very quickly and safely. In this case, the integrated solution for control and safety tasks is Projekt1 05.04.17 09:23 Seite 1

suitable for both simple and complex applications. As it has a modular structure, it can be expanded any time to suit your requirement. Integration does not require any complex installation or handling processes.

Today the hospital engineers are happy with the performance of the automation system PSS 4000 controlling the switching of HV power supplies and overall smooth trouble-free operation over the past four years of the initial installation.

For that reason, they have now commissioned White Electrics to expand the automation system to include safe control of the low-voltage circuit breakers.

“The ability to expand PSS 4000 is so easy to undertake that even further expansion is planned to be installed over the next two years,” said White.

He added that it is a very successful

“Two independent substations supply power to this particular hospital. If these are unavailable, a diesel generator steps in.” project and a “win-win” for all those concerned.

From classic automation technology to building automation

“In the end, the key factor in selecting the automation system PSS 4000 from Pilz was the solution for control and safety tasks, with its smart diagnostic functions, was simpler and more economical than comparable solutions from other suppliers,” said Moffat.

What’s more, with its decentralised

IO modules it is small, compact and requires little space in the control cabinet.

The Industry 4.0-compatible automation system PSS 4000, already established in industry has now arrived in building electrics and automation.

As in automated production plants, it provides protection for people operating in the area and saves expensive equipment from damage. PACE Pilz Australia www.machinesafe.com.au 1300 723 334

JUNE/JULY 2017 www.pacetoday.com.au 25

SENSORS

The challenges of sensing for oil and gas PACE looks at why there are many challenges with using sensors in the oil and gas industry. High performance with excellent accuracy are just two of the key facets for success in such a highly competitive arena.

P

ossessing all the equipment to keep tabs on an LNG plant, gas wellhead or other critical site requires a variety of different sensors and the expertise to integrate them. There are some commonly used sensors in the oil and gas industry and some of the biggest challenges chemical processors face are when it comes to using linear variable differential transformers (LVDTs), pressure and temperature sensors.

Pressure sensors deployed in drilling, exploration and other oil and gas environments need to be high performance with high reliability and accuracy. Liquid/gas compatibility and potential contamination are some of the main challenges associated with sensor use.

Certain sensor technologies are limited in the material that can be

26 www.pacetoday.com.au JUNE/JULY 2017

used or the method in which they are sealed. For example, ceramic pressure sensors are clamped to a metal process connection with an O-ring seal.

While ceramic has good compatibility with various liquids and gases, O-rings need to be selected carefully and considered in the compatibility process. O-rings can also have a limitation in temperature. Pressure sensors using thin-film and bonded foil strain gauge technology also have limitations in the base material of the sensing element.

The oil/gas process industry uses NACE MR0175 as an industry standard for material. Bestech offers appropriate material as a standard sensor material to suit various applications. For example, the 21D/ DC RFID series from Bestech offers a solution combining industrial

“Subsea applications pose special challenges for reliable LVDT operation, due to the presence of chemically hostile seawater that attacks common metals.” pressure sensing with RFID wireless communication and data logging.

The pressure transponders combine sturdy, tried-and-tested industrial pressure transmitters and advanced RFID (radio frequency identification) wireless technology.

The D line OEM piezoresistive transmitters used to measure pressure are based on chip-in-oil technology.

They come in robust, laser-welded, hermetically sealed stainless-steel housing, which is filled with oil for pressure transmission, contains the pressure transducer and the

ultra energy-efficient compensation electronics with I2C interface.

Also available are IECEx-certified – meeting Australian and New Zealand standards for working in explosive environments – pressure transducers, transmitters and digital gauges. Intrinsically safe pressure and submersible level sensors from Bestech Australia are manufactured to meet requirements for Class I Division 1 Zone 0 hazardous locations.

LVDT sensors have a very stable output signal due to their differential transformer design. They are designed

SENSORS

motion of the magnetic core, any other movements such as the rotation of the core around the axis will not affect its measurements as the moving core does not necessarily contact the inside of the stainless-steel housing tube. It also moves with almost no friction, thus, making the LVDT a highly reliable target contacttype sensor.

Subsea applications pose special challenges for reliable LVDT operation, due to the presence of chemically hostile seawater that attacks common metals. Linear position sensors can become quickly corroded and pitted. Temperature, salt level and micro-organisms in seawater can also accelerate for a wide range of industrial and corrosion rates, leading to premature scientific position feedback or sensor failure. measurement applications. LVDT To survive subsea environments, sensors have high repeatability and LVDT position sensors must be show the exact same measurement housed in special alloys that support on restarting after power outage with long-term operation in different D _ P A information C E A M S Fbeing E B _ 1 3 . p elements. df P aAsg aehousing 1 9and / 0core 1 / 1 3 , no Apositional lost. Apart from the uni-axial linear made from stainless steel will not

“Depending upon the temperature, salinity, oxygen levels and depths of applications, the LVDT, with its hermetic seal and non-contacting operation, is often the only technology that can deliver accurate and reliable performance in subsea conditions.”

survive well in many underwater applications, the LVDT casing must be composed of an alloy that provides chemical resistance to seawater and other corrosive acids to provide long-term reliable operations for many years. Reliability is critically important due to the cost of replacing subsea hardware.

Depending upon the temperature, salinity, oxygen levels and depths of applications, the LVDT, with its hermetic seal and non-contacting operation, is often the only technology that can deliver accurate and reliable performance in subsea conditions. As Subsea LVDTs provide the same reliable performance as standard units but with more chemical resistance to seawater, they are replacing less reliable linear position technologies such as pots and magnetorestrictive sensors for position measurement in underwater applications. Spring-loaded LVDTs 1 0 : 0 stationary 0 A M LNG tank measure movement caused by earthquakes,

floods and hurricanes, as well as vibration of subsea/underwater tanks.

TIM Infrared temperature sensors and real-time monitoring cameras are frequently used for leak detection and cool-down monitoring at LNG plants. They provide continuous, non-contact temperature monitoring, wide measuring range (from –50 degrees Celsius and up to 1800 degrees Celsius).

Based on infrared imaging technology, these sensors provide visual thermograms that are images of radiation in infrared range of 9-14μm, detecting anomalies during pipeline operation. The thermal imaging camera detects heat patterns, temperature values, and is based in a heat-resistant, rugged, and waterproof housing, rendering infrared radiation – such as that given off by warm objects or flames – into a visible light representation in real time. PACE Bestech Australia 03 9540 5100 www.bestech.com.au

JUNE/JULY 2017 www.pacetoday.com.au 27

SENSORS

New series of diffuse photoelectric sensors with smart features For too long diffuse photoelectric sensors have had many problems with consistency and accuracy. A new range by ifm efector is said to not only meet the needs of manufacturers but come with a range of smart features that offer reliability that is currently missing from most diffuse sensors.

T

he three main groups of photoelectric sensors used in manufacturing – throughbeam, retro-reflective and diffused – play an important role in the automation of manufacturing processes.

They detect the distance, absence or presence of an object moving along the production line. Of the three, diffused sensors are most suitable for manufacturers looking to cut costs and improve efficiency because they only require installation at one point rather than two, as is required with throughbeam or retro reflective sensors.

However, the cost per unit savings that come from choosing a diffused photoelectric sensor over others, are usually undone by the sometimes unreliable and limited sensing capabilities that can cause interference during production and even downtime.

For manufacturers, removing or reducing errors during production without the need for additional expensive equipment is the key to sustainable and competitive business.

Reactions to colour, shape and surface

Most standard diffuse sensors are reactive to target characteristics, such as colour, surface irregularities, shape, position and reflectivity. Since they also require a certain amount of light

to be reflected back off the target, some colours or surfaces are difficult for the photo eye to detect.

For example, dark matte surfaces such as automobile tyres have a reflective index as low as 1.5 per cent, compared to 400 per cent for polished stainless steel. Both situations are problematic for manufacturers, because most manufacturing environments are built around robust, highly reflective surfaces.

Even reflective tape on high visibility jackets can cause havoc with sensing equipment, making the range seemingly impossible to control, even when the range is adjusted.

It is not uncommon for a standard diffused mode sensor with a specified range of 38 centimetres to falsely detect another reflective object that is six feet or further away from the sensor.

Positioning

Another problem with standard diffuse photo-electric sensors is positioning.

Most diffuse sensors can guarantee a return light signal only if the shiny surface of the material presents itself perfectly parallel to the sensor lens.

For angled or round parts; such as bottles or shiny cans, typical diffuse sensors would struggle to detect the targets accurately, making them unsuitable for this type of application.

Setting the range

Standard diffuse photo-electric sensors require the target range to be set each time a batch is switched, and when smaller or larger parts are expected to pass the sensor at various distances.

Usually workers will need to place the target at the required range to ‘teach’ the sensor each time there is a change in object.

Since many sensors have different teaching methods, staff usually need to be consulted or refer to instructions in order to perform the teach function – further extending the disruption to production.

Why this is bad for business

Sensing faults or inaccuracies that lead to incorrect switching and unplanned downtime are counterproductive to the automation process, and costly to the business. Even minor stoppages during line changeover have a significant effect on output and overall profits.

Additionally, false signals can lead to quality issues as objects collide and crash. In the case of broken sharps like glass bottles, safety during clean-up becomes another issue.

For this reason, companies that deal with angled, round or highly reflective objects typically would need to install retro-reflective or thru-beam systems, which are considerably more expensive to purchase and complex to install, as they require additional components to be mounted.

The solution Standard diffuse photo-electric sensors require the target range to be set each time a batch is switched.

28 www.pacetoday.com.au JUNE/JULY 2017

In the past, standard diffused sensors have been earmarked as unreliable instruments for those manufacturers with complex sensing needs. However, new to market PMDLine sensors from IFM are the world’s first standard photoelectric sensors with ‘time of

Positioning is a problem with some diffuse photo-electric sensors.

flight’ measurement (PMD), and advanced smart features that improve sensing reliability far beyond the capabilities of current standard photoelectric sensors.

Benefitting from ‘time of flight technology’, PMDLine sensors provide colour independent detection of targets to ranges of two metres, and are not affected by shiny surfaces, including reflective tape used on safety vests.

Since PMDLine sensors do not require the target to set the range, they can be set up in the workshop or pre-programmed ready for use, resulting in less downtime during production and also quicker installation and replacement in a breakdown situation.

Where standard photo-electric sensors fail, PMDLine Sensors offer greater flexibility in the mounting position of the sensor as it does not need to be mounted perpendicular to the target.

The result of such integrated technology is a product that serves the sensing needs of manufacturers – improving production and reducing downtime, while remaining cost efficient to purchase, install and operate. PACE ifm efector www.ifm.com 1300 365 088

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Would you like to benefi benefitt from from aa powerful, powerful, modular modular drive drive system system that thatminimizes minimizes your variants, simplifi simplifies handling and and reduces reduces storage storage costs? costs? We’re We’rein! in!With With es handling IndraDrive ML we off offer megawatt-sized universal inverters up to 4MW with er megawatt-sized universal inverters with certified safety certified safety and intelligent control functions on board. technology and technology intelligent control functions on board.

To find out more, please contact: Bosch Rexroth Pty Ltd Phone: (03) 9580 3933 Email: mel@boschrexroth.com.au Visit: www.boschrexroth.com

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QUALITY CONTROL

Putting ISO Standards into a realworld context While ISO standards play an important and omnipresent role in design, SMC Pneumatics argues that at the same time, they are not the be-all and end-all. Engineers should be prepared to occasionally look beyond the standards in their quest for the best and most useful industrial solutions.

T

he Geneva-based International Organisation for Standardisation (ISO), an independent non-government organisation that counts 163 national bodies as members, publishes standards covering almost every industry.

The scope of its interest is therefore mind-bogglingly large. To date, the organisation has published more than 21,000 standards and associated documents relating to everything from the phones we use to what we have for

breakfast, to the cars we drive.

And it does a good job. ISO standards help ensure the quality, safety, and efficiency of industry and the products we use. They help make the world a better place.

But are standards the end of the story? Should designers and engineers always conform to standards or are there cases where, by not following published standards, there is a possibility that they can actually manufacture better, more efficient or even safer products?

“Many within industry feel that by sticking to the standard, they will end up with ‘orphaned’ components, which are difficult to replace or use with other components.”

According to Sydney-based SMC Pneumatics, the answer to this last question is yes. While standards are valuable and worthwhile, they don’t always deliver the best product solution.

Could designers and engineers make better and safer products if they didn’t follow published quality control standards?

30 www.pacetoday.com.au JUNE/JULY 2017

Depending on what they are making, manufacturers and designers who sometimes think outside the box can deliver products that are superior to the products of those who don’t.

Put simply, standards can be left behind in cases where they don’t adequately address the requirements of the application in question; cases where the standard fails to include important criteria that need to be included in the new design.

As SMC sees it, in such cases, trying to conform to the standard can compromise the design or process requirements and fail to deliver the best solution.

Because of the sheer scope of what they are expected to cover ISO, standards sometimes fall short.

For SMC, it comes down to first fully understanding the application being considered and then designing the product.

For example, within the food and beverage sector, hygiene is of paramount importance. With the health of consumers in mind, manufacturers rightly place this at the top of their priority lists.

However, ISO standards relating to pneumatic valve and cylinder design do not specify ‘hygienic design’.

So manufacturers who slavishly follow the standard are not able to access some of the important hygienic considerations available to fully satisfy current industry requirements.

QUALITY CONTROL

“Depending on what they are making, manufacturers and designers who sometimes think outside the box can deliver products that are superior to the products of those who don’t. ”

More broadly, across most industries, cost of ownership, energy efficiency, safety, functionality and economy are key concerns.

The use of technology improvements and innovative features can be the difference between an industry-leading product and a dud.

The Organisation for Standardisation (ISO) has published more than 21,000 standards.

Innovation happens quickly. It is unreasonable to believe ISO, with its large scope of concerns, could keep up with today’s pace of change.

There is still a belief that products that meet standards are safe, readily available, cost competitive, and can be interchanged with other brands.

Many within industry feel that by sticking to the standard, they will end up with ‘orphaned’ components, which are difficult to replace or use with other components.

The belief is that, in the long run, the product that meets the standard will be the safest option. According to SMC, this is not the most effective approach.

Businesses with this perception are asking themselves the wrong questions.

They should be asking themselves what tasks they need the product to perform and what features it should have. When they do this, businesses often find that the product that meets the standard is not always the most appropriate selection. PACE SMC Pneumatics 1800 763 862 www.smcworld.com

DPI620 Genii-Mod Calibrator & Communicator Electrical, Freq, Temp & Press Calibrator & HART/FF Comm DPI620G provides simulataneous measurement & source capabilities for setup, testing and calibration of most types of process instruments including transmitters, transducers, gauges, switches, proximity detectors, RTD, T/C and valve positioners measurements, capable of the highest precision at the widest temperature range.

Phone 1300 735 295 Email InfoIndustrialAU@thermofi sher.com

Find out more at thermofisher.com.au/EIP For Research Use Only. Not for use in diagnostic procedures. © 2017 Thermo Fisher Scientific Inc. All rights reserved. All trademarks are the property of Thermo Fisher Scientific and its subsidiaries unless otherwise specified. 1490051653 JUNE/JULY 2017 www.pacetoday.com.au 31

TEST AND MEASUREMENT

Improving parts management and overcoming import challenges PACE looks at how incremental encoder testing with quality equipment can help mining companies improve their performance and better manage their stock, leading to less downtime and increased profits.

Encoders come in many variations and differ depending on the application.

O

n many mine sites, with equipment and infrastructure being as much as 30 years old, spare parts management of machinery can be an arduous task, especially when sourcing encoders for discontinued models or imported machinery.

As mining companies move increasingly towards automation of processes, and roll out strategies for increased visibility of operations, sourcing spare parts takes on a critical

role in the predictive maintenance of machinery.

Encoders are an important part of production in many industries, acting as feedback transducers for motorspeed control, sensors for measuring, cutting and positioning, and as input for speed and rate controls.

Australia’s import challenges

When it comes to importing from overseas, the decision to do so should be made according to your

“In many industries, the non-availability of spare parts, as and when required, contributes to as much as 50 per cent of total down time, which can lead to hundreds of thousands of dollars in lost.”

32 www.pacetoday.com.au JUNE/JULY 2017

manufacturing needs. For example, do you sell a commoditised product that isn’t time-sensitive, or do you sell a highly specialised product that has to be produced on a reliable timetable?

In most operations, time equals money. So, while importing parts may save money on initial outlay, in the case of quality issues or delayed deliveries, imports can end up costing a business considerably in downtime and productivity.

Since encoders come in many variations and differ depending on the application, motor type, brand and year of manufacture, it is near impossible for one supplier to stock each variation.

If you are looking overseas to purchase, the stakes are higher because of longer delivery times and, in some cases language barriers, may slow down research.

Another problem that stretches industry wide is the demand Operating with limited spare parts can mean no back up is available.

for smaller and more complex machinery. This is more so in the case of imported equipment, as design changes are taking place faster in developed countries because new machine capabilities require new encoders.

Older models are gradually being phased out, moving further down the production line, and growing increasingly hard to source.

Why industry should be concerned

Lean manufacturing focuses on cutting costs and reducing waste and is beneficial to production processes, but it can make the job of spare parts management difficult. In order to reduce the amount of capital tied up in spare parts inventory, many organisations operate using predictive maintenance techniques; planning for, and having parts available when they are due to be replaced.

However, in the case of an

TEST AND MEASUREMENT

The EncoderLAB is designed to both test and simulate square wave encoder signals. unexpected product failure, operating with a limited spare parts inventory can leave you with no immediate back up and a long wait on your next order, with the trickle-down effect impacting productivity.

In many industries, the non-availability of spare parts, as and when required, contributes to as much as 50 per cent of total down time, which can lead to hundreds

of thousands of dollars in lost productivity per annum - something no company can afford.

In the auto production industry for example, one minute of stopped production, or downtime, costs an average of $22,000, with larger companies recording loses of up to $50,000 per minute. Such huge losses, while not directly linked to encoder failure; give a good indication

“In most operations, time equals money. So, while importing parts may save money on initial outlay, in the case of quality issues or delayed deliveries, imports can end up costing a business considerably in downtime and productivity.”

of the critical issues that can arise from not taking the time to help improve your spare parts management strategy.

Some industries like food manufacturing are already operating on wafer thin margins, with suppliers continually demanding cheaper, highquality products within a particular timeframe.

Unplanned downtime not only costs a significant amount of money, but can also hinder a company’s ability to meet deadlines, jeopardising important supplier relationships and future orders.

Incremental encoder testing with EncoderLAB In response to the need for incremental encoder testing, PCA

has developed an encoder testing instrument with facility for computergenerated performance reports and historical logging for quality control records.

The EncoderLAB is two incremental encoder instruments in one housing. It can test or simulate all encoder signals. Features include: • The ability to test parameters of an encoder within a couple of shaft revolutions.

• The encoder simulator emulating six incremental encoder outputs.

• Being able to test an encoder without having to run the machinery it is installed into. PACE

Plant Control and Automation 02 9482 3733 www.pca-aus.com.au

JUNE/JULY 2017 www.pacetoday.com.au 33

LEVEL MEASUREMENT

Radar the answer to liquid level challenges Being able to accurately measure liquid levels from the outside is a challenge. Vega offers a solution.

L

iquid level measurement is integral to many applications, ranging from hydraulic fluids, diesel fuel tanks, and water and wastewater, to biohazards and even deionised or potable water. The problem is finding a method with guaranteed accuracy that can address a wide range of measurement scenarios and challenges.

Some of the most common challenges in liquid level measurement are small vessels, internal obstructions and poorly reflective liquids.

Addressing these challenges requires a device that can effectively measure from the outside of a vessel, no matter the chemical composition of the liquid, and despite constant changes in level.

For this application, non-contact radar level sensors offer the best accuracy and ease of use.

One of the main methods these instruments use is Frquency Modulated Continuous Wave radar, which works by sending out a microwave signal that bounces off the product surface and returns to the gauge. A transmitter measures the time delay between the transmitted and received echo signal, and then the on-board microprocessor uses this information to calculate the distance.

While there are a range of radar level sensors on the market, the Vegapuls 64 is the first product for liquids measuring at a frequency of 80GHz. Why is this important?

Because the higher the dynamic range of a radar sensor, the higher the measurement certainty and the wider the range of applications that the sensor can be used for.

Until now, a radar sensor with a transmission frequency of 26GHz

The Vegapuls 64 offers the smallest antenna on the market.

“The sensor’s high dynamic range also means that poorly reflective liquids are no longer a concern; it promises reliable measurement even with surface foam.” and an 80mm diameter antenna had a beam angle of approximately 10 degrees. With the same size of antenna, the Vegapuls 64 has a beam angle of only 3 degrees. This allows better focusing of the radar beam, which means the sensor can be used even in vessels with internal installations or heavy build up on the walls, as its focused microwave beam simply avoids these obstacles.

The sensor’s high dynamic range also means that poorly reflective liquids are no longer a concern; it promises reliable measurement even with surface foam, turbulent product surfaces and condensation or buildup on the antenna. According to Vega, the Vegapuls 64 offers the smallest antenna on the market, making it suitable for use with small storage or process vessels in a wide range of industrial sectors. PACE

The higher the dynamic range of a radar sensor, the higher the measurement certainty.

34 www.pacetoday.com.au JUNE/JULY 2017

VEGA Australia Pty. Ltd. www.vega.com 02 9542 6662

, D E E N U .

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RELY ON AUSTRALIA’S MANUFACTURING, MINING AND INDUSTRIAL HUB 70,000 monthly users can’t be wrong. Find what you’re looking for with over 12,000 business listings and 8,000 specific product listings. Access relevant information and resources, empowering you to make a qualified purchase decision. You can always rely on your industry hub.

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NEW PRODUCTS

Power distribution solution INTEGRATION of ABB’s MNS-Up with the ABB Ability Mission Critical Power Control System enables a connected solution to ensure the reliability of critical power applications such as data centres, process industries or hospitals.

ABB’s MNS-Up system integrates uninterrupted power supply (UPS) and switchgear technologies into a single and compact system. ABB Ability Mission Critical Power Control System is part of ABB’s portfolio of digital offerings that enable customers to do more with their assets, providing local and remote system visualisation, control and remote diagnostics for the highest power reliability.

According to the company, MNS-Up enables users to save up to 10 per cent capital in electrical infrastructure. It also requires up to 30 per cent less space compared to traditional architectures and can be up and running as much as 20 per cent faster due to reduced installation and commissioning time. It has been developed for mission-critical facilities that demand zero downtime.

ABB Australia 1800 222 435 www.abbaustralia.com.au

Rugged linear displacement transducer AMTEK Factory Automation has introduced an embedded linear displacement transducer (LDT) with shock and vibration resistance for demanding mobile hydraulic applications. With shock resistance of 1000Gs and vibration tolerance of 30Gs, the new Gemco 958A transducer provides long life in extreme operating environments.

The 958A is designed for dependable, high-accuracy performance in mission-critical mobile heavy equipment applications. It offers accuracy and reliability with high resolution and precision repeatability.

The transducer uses the latest generation of Amtek’s field-proven magnetostrictive position-sensing technology to give absolute analogue position, accurate to 0.04 per cent of the programmable sensing distance. A variety of

analogue outputs are available to meet user needs.

The rugged, rod style LDT fits entirely inside a hydraulic or clevis style cylinder. This protects the transducer from outside conditions and allows use where there is no room for external devices.

It can be powered from 8 to 30 VDC at 1.6 watts, making it easy to fit into a variety of systems. It includes a unique built-in diagnostics capability that displays the health of the unit and helps aid in troubleshooting problems if they occur. The 958A is easy to install and set up, according to the company. Units can be ordered in span lengths from 50mm-2540mm and come standard with either integral cable assemblies, bare leads or M12 style connectors Amtek Factory Automation www.amtekfactoryautomation.com

Bluetooth compatible clamp-on earth tester THE new Hioki FT6380 and Hioki FT6381 are precision earth resistance measurement clamp-on testers. Precise voltage is injected and by means of current measurement, earth resistance is computed and displayed.

The Hioki FT6381 is the Bluetooth compatible version providing automatic report generation via Android phone including date, time, measurement value and GPS-location. Up to 2000 data points can be stored internally for later downloading. The dual slim jaws clamp up to 32mm diameter conductors. Maximum rated voltage is 600 volts to earth, and the instrument meets EN 61010 safety standards. Magnetic interference is 10mA or less in an external magnetic field of 400A/m at 50/60Hz AC. Power Parameters 1800 623 350 www.parameters.com.au

36 www.pacetoday.com.au JUNE/JULY 2017

2017

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NEW PRODUCTS

Code scanner THE Wenglor series C5KC and C5PC 1D/2D stationary code scanners eliminate time-consuming software installation and configuration. The auto-setup, auto-focus and newly developed decoding algorithms provide outstanding reading performance against almost any background. Thanks to the integrated Ethernet port, the sensors are a solution for customer requirements in the field of Industry 4.0.

Scan settings can be accessed via the Wenglor WebLink user interface for optimised reading of damaged and high-resolution codes. They offer the smallest available format for 1D/2D code scanners, making them ideal for use in extremely compact machines and, thanks to a reading

speed of 60 scans per second, they’re suitable for applications with high throughput rates too.

The code scanners are suitable for a large range of applications including product identification and traceability, checking for completeness and quality inspection of 1D/2D barcodes and reading of all common 1D/2D codes, as well as scanning of 1D/2D barcodes on all surfaces such as PCBs, metal and pallets. With their extensive range of capabilities, these scanners are ideal for the automotive, pharmaceuticals and foods industries.

Treotham Automation 02 9907 1788 www.treotham.com.au

Light curtain with Profinet interface WITH the Profinet interface integrated in the CML 700i, Leuze electronic makes possible simple and fast integration of this light curtain in the fieldbus environment without additional gateway box and extra software.

Configuration is carried out directly via the large display, using Leuze Sensor Studio or directly via the PLC, which saves the settings and makes it possible for devices to be replaced without having to re-configure.

The CML 700i Profinet model is equipped with an integrated switch for setting up a ring or linear topology. Through cascade mounting with a dead zone of just 23mm between beams, fast response times and the detection of transparent objects, this model is able to perform gapless object tracing, e.g. on conveyor lines.

The data can be transmitted with a speed of 100MBit/s.

Depending on the length (up to 2880mm), the measuring light curtain makes the data available cyclically within 1ms to 53ms.

The maximum length of the measurement data is 222 bytes, and the individual values of the individual beams can be output at any position.

Leuze Electronic 1300 538 933 www.leuze.com

Rugged tablet with RTK-GNSS technology Panasonic has announced the launch of what it says is the world’s first tablet using centimetre-level RTK GNSS technology, in collaboration with u-blox.

Toughpad, the new version of Panasonic’s professional grade notebooks family, is specifically designed for precision agriculture, machine control and robotic guidance applications in harsh environments and conditions. Embedded in the tablet is a u-blox NEO-M8 GNSS receiver module delivering high integrity and precision in demanding applications world-wide.

First successfully tested for collecting snow in Hokkaido, the tablet uses the company’s satellite positioning technology combining a satellite radio receiver module, wireless WAN, and a single band Real Time Kinematic (RTK) Global Navigation Satellite System (GNSS) receiver connected to an external antenna. This system enables high precision positioning down to centimetre-level in open sky conditions.

Panasonic Australia 03 8710 3200 www.panasonic.com/au

38 www.pacetoday.com.au JUNE/JULY 2017

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Dust and buildup on the antenna? No problem!

The future is 80 GHz: a new generation of radar level sensors

VEGAPULSÂ 69 is designed specifically for level measurement of bulk solids.

Even in dusty conditions, it always provides precise readings. Dust in the silo or buildup on the antenna have no effect.

This radar sensor also features unrivalled focusing at a frequency of 80Â GHz. Simply world-class! www.vega.com/radar