Control Engineering 2024 MayJun

CONTROLENG.COM

PID series part 5: Good/bad tuning | 33 Back to the future of PLCs, programming | 34, 63 Drives; Cybersecurity | 38, 42 Networking; Testing application | 44, M1

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Vol. 71 • No. 3

Contents MAY/JUNE 2024

16-30 How to develop

automation engineers

How are you getting, training and keeping qualified engineers? See our annual workforce and development salary survey research and advice section. Cover image courtesy: CDM Smith

INSIGHTS

ANSWERS

7 | May article sampling of headlines, authors, companies, links

26 | How to progress in engineering, automation: 3 phases

9 | Market Update: Mergers in automation

28 | Solving the skills shortage requires an innovative approach

10 | Technology Update: Choosing the right computing paradigm for industrial transformation

NEWS 12 | Automate 2024 roundup, recap: How to accelerate automation’s benefits 15 | Think Again: Control Engineering, in its 70th year, joins WTWH Media

ANSWERS 16 | Results are in: Control Engineering Career and Salary Survey, 2024

30 | Spectacular performers fly with motion controls, STEM, not CGI

p.34

33 | Advanced process control: One page of PID spotlight, part 5; Seven pages online 34 | Back to the future of the PLC 38 | Power quality, harmonics: How to select a variable frequency drive (VFD) 42 | Crafting the right IT/OT cybersecurity strategy for the journey ahead

p.42

44 | Picking the right MES or automation solution for a life sciences application 62 | Product of the Year: What would make your job easier?

20 | Get engineering salary survey advice from Control Engineering research

INSIDE MACHINES

22 | Automation engineer pipeline: The making of an automation professional

M1| Make exponential gains now: Automation, I/O, mechatronics

(after 45)

p.M1

CONTROL ENGINEERING (ISSN 0010-8049, Vol. 71, No. 3, GST #123397457) is published bimonthly by: WTWH Media, LLC; 1111 Superior Ave., Suite 2600, Cleveland, OH 44114. Periodicals postage paid at Cleveland, OH and additional mailing offices.

POSTMASTER: Send address changes to CONTROL ENGINEERING, 1111 Superior Ave., Suite 2600, Cleveland, OH 44114. Scott McCafferty, Co-Founder. CONTROL ENGINEERING copyright 2024 by WTWH Media, LLC. All rights reserved. CONTROL ENGINEERING is a registered trademark of WTWH Media, LLC, used under license. Circulation records are maintained at WTWH Media, LLC, 1111 Superior Ave., Suite 2600, Cleveland, OH 44114. Telephone: 630/571-4070. E-mail: ctle@omeda.com. Publications Mail Agreement No. 40685520. Return undeliverable Canadian addresses to: WTWH Media, LLC, 1111 Superior Ave., Suite 2600, Cleveland, OH 44114. Email: ctle@omeda.com. Rates for nonqualified subscriptions, including all issues: USA, $165/yr; Canada/Mexico, $200/yr (includes 7% GST, GST#123397457); International air delivery $350/yr. Except for special issues where price changes are indicated, single copies are available for $30 US and $35 foreign. Please address all subscription mail to: CONTROL ENGINEERING, WTWH Media, LLC, 1111 Superior Ave., Suite 2600, Cleveland, OH 44114. Printed in the USA. WTWH, LLC, does not assume and hereby disclaims any liability to any person for any loss or damage caused by errors or omissions in the material contained herein, regardless of whether such errors result from negligence, accident or any other cause whatsoever.

control engineering — www.controleng.com

May/June 2024

|3

Vol. 71 • No. 3

Contents MAY/JUNE 2024

INNOVATIONS New Products for Engineers Too many for print this month: Go online for these products and more! Industrial USB hub series (a world’s first, says Moxa), process gas analyzer, circuit breaker ystem with EtherNet/IP, Embedded IoT device for automation and industrial applications, fanless open-frame power supplies, 1kW wireless charging system for robotics, high-resolution thermal cameras, SCADA software.

See more products online www.controleng.com/products 63 | Back to Basics: How to reduce workload using reusable PLC components Multiple programmable logic controller (PLC) platforms support pre-packaged code to reduce programming time.

NEWSLETTERS ONLINE Control Systems Newsletter • Back to the future of the PLC; PID spotlight; Four benefits of software-defined controls

CE Edge & Cloud Computing Newsletter • Speed up reactions with edge computing.

5 selections from the editor CE Newsletter • Best of Control Engineering last month. PLC webcast, videos, PID series, future cybersecurity Stay ahead. Subscribe! www.controleng.com/newsletters uGlobal System Integrator Report

Did you see profiles about companies receiving the System Integrator of the Year award, case studies and more? www.controleng.com/GSIR Contact: kparker@cfemedia.com; cvavra@cfemedia.com. control engineering — www.controleng.com

Control Engineering eBook series, now available: Summer Edition AppliedAutomation eBook Topics include: Next-generation, open automation infrastructure controller; Think redundantly about automation controllers without high costs; Control system integrators: How to excel with automation upgrades; New cost analysis: Open process automation saves 52% versus DCS. Learn more at: www.controleng.com/ebooks uProtecting Critical Infrastructure eBook

Topics include: How to lower industrial cybersecurity risk: Help from CISA, INL, ARC Advisory Group; Overcoming SCADA integration cybersecurity challenges; 8 steps to defend against foreign and hidden threats in industrial operations; Six best practices for OT cybersecurity.

More topics at: www.controleng.com/ebooks uControl Engineering digital edition

Reading on paper? Also take advantage of useful links in the digital edition.

Click on headlines to see online version with more text and often more images and graphics. Also download a PDF version. www.controleng.com/ magazine

May/June 2024

|5

| EC17USA |

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With blink-and-you’ll-miss-it dimensions, the CX7000 provides powerful automation anywhere it’s needed. An ARM Cortex™-M7 processor and TwinCAT software help you tackle wide-ranging control tasks previously handled by bulky PLCs. Beyond the configurable options of 8 digital inputs, 4 digital outputs, 2 encoder inputs, 2 analog 0…10 V inputs and 2 PWM outputs built in, the CX7000 directly connects to a gargantuan range of Beckhoff I/O terminals.

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Online Highlights controleng.com

INSIGHTS u NEW RESEARCH Part 1: Made in America research shows enhanced production efficiencies (A)

www.controleng.com/made-in-america www.controleng.com/webcasts/research-review-control-systems-hmi-scada-and-plcs u INTERNATIONAL: CE China: How to produce flexibly using mobile robots, machine vision u WEBCASTS

www.controleng.com/articles/more-answers-about-how-to-advance-intelligent-data-sharing-analytics www.controleng.com/articles/webcast-preview-how-to-achieve-operational-excellence-in-modern-monitor-and-control-with-edge-computing www.controleng.com/articles/webcast-preview-iiot-automation-sensors-to-fit-edge-applications www.controleng.com/webcasts/motors-and-drives-are-you-advancing-automation-efficiencies-with-smarter-components-systems

(A)

u Watch www.controleng.com/webcasts for:

July 16: SCADA: Incremental upgrades or replacements? Ask these questions for best results; Jason Israelsen, PE, senior control engineer, APCO Inc.; Joseph Mazzola, general manager, McEnery Automation Aug. 1: How to automate: The mechanics of loop tuning; Ed Bullerdiek, control engineer, retired

NEWS

(B)

u Top 5 Control Engineering content: May 20-26; Manufacturing in space: Funding for ISS

www.controleng.com/articles/top-5-control-engineering-content-may-20-26-2024 www.controleng.com/articles/funding-for-technology-development-for-iss-announced

ANSWERS u PID spotlight, part 4: How to balance PID control for a self-limiting process;

Ed Bullerdiek, retired control engineer

www.controleng.com/articles/pid-spotlight-part-4-how-to-balance-pid-control-for-a-self-limiting-process

(C)

u Gaining the edge: Reducing costs, improving outcomes with edge AI; Lindsay Hilbelink

is global strategic marketing manager for Eurotech. (B)

www.controleng.com/articles/gaining-the-edge-reducing-costs-improving-outcomes-with-edge-ai u Choosing technology for streamlined engineering; Kyle Harrison, HMI product

manager, Siemens. (C)

u Impact of CMMC on the DoD supply chain; Joe Coleman, cybersecurity officer,

Bluestreak Consulting

www.controleng.com/articles/the-impending-impact-of-cmmc-on-the-dod-supply-chain u How to safely, sustainably absolve industrial malodors; Lisa Haupert, Ph.D.,

chief scientific officer, Ecosorb

(D)

www.controleng.com/articles/how-to-safely-sustainably-absolve-industrial-malodors-with-standardized-formulations u Forging open and unified industrial network architecture with TSN and single-pair ethernet;

Lisa Chang, product manager, Moxa Inc.

www.controleng.com/articles/advancing-industrial-connectivity-with-tsn-and-single-pair-ethernet/ u Benefits of using mixed valves in processing, industrial applications; Christine Tarlecki

is a marketing coordinator at ThermOmegaTech (D)

www.controleng.com/articles/benefits-of-using-mixing-valves-in-processing-industrial-applications

(E)

u Industrial robot safety considerations, standards and best practices to consider;

Herbert Post is VP of health and safety at TradeSafe (E)

control engineering — www.controleng.com

May/June 2024

|7

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INSIGHTS

MARKET UPDATE

Automation mergers, acquisitions, capital markets analysis in April uORCHARD ROBOTICS Premiere cut, Massachusetts, aiming to drive technological advancement and market expansion.

Automation, RedViking and Siemens were 4/1/24 Lincoln Electric Holdings Inc. among companies involved in recent mergacquired RedViking, a privately held autoers and acquisitions. The automation marmation system integrator based in Plymket continues to experience a tremendous outh, Michigan. RedViking develops and number of mergers and acquisitions (M&A) integrates autonomous guided vehicles and capital markets activity because of (AGVs) and mobile robots, custom assemautomation market growth, consolidation bly and dynamic test sysopportunities and strength tems and manufacturing of many of the companies.

The automation execution system (MES) Bundy Group’s relationships market continues software. include control system inteto experience 3/28/24 Orchard Robotgration, robotics, automated ics, the company enabling material handling, automaa tremendous precision crop managetion distribution, artificial number of mergers ment with robots and AI, intelligence and cybersecuriannounced their $3.8M ty; more activity is expected. and acquisitions raise, across a seed round (M&A) and capital led by General Catalyst, and April 2024 automamarkets activity. a pre-seed led by Contrary. tion transactions 3/26/24 Vinci Energies 4/21/24 Siemens AG acquired Premiere Automation LLC., an agreed to acquire the industrial drive industrial controls and robotics specialist technology (IDT) business of ebm-pain Charleston, South Carolina. Premiere pst. The business, which employs around Automation provides project manage650 people, includes intelligent, integratment, controls and robotics integration ed mechatronic systems in the protective and training services. extra-low voltage range and motion con3/21/24 SER, a leading global Intellitrol systems. The planned acquisition will gent Content Automation software vendor complement the Siemens Xcelerator portin the Enterprise Content Management folio and strengthen Siemens as a provider market, announced that TA Associates, a of flexible production automation. global private equity firm, agreed to make 4/11/24 Graham Partners, an investa strategic growth investment. ment firm focusing on advanced manufac3/20/24 Sonepar agreed to acquire the turing, has acquired E Tech Group. Based Michigan-based distributors, Madison in West Chester, Ohio, E Tech is an indusElectric Co. and Standard Electric Co., trial automation systems integrator serving distributors of electrical and industrial life sciences, data centers, consumer packproducts and services to contractor and aged goods, industrial and other sectors. E industrial customers.

Tech helps customers integrate and support 3/18/24 Fortifi Food Processing Soluautomation in regulated environments. tions, provider of food processing equip4/8/24 Industrial Device Investments ment and automation solutions, completed LLC initiated a strategic partnership with acquisition of Reich Thermoprozesstechnik Wasik Associates LLC, a manufacturer of GmbH, a provider of thermoprocessing sysElectron Beam Processing Systems in Dra-

‘

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control engineering — www.controleng.com

Industrial networking groups merge to advance integration technology, automation FIELDCOMM GROUP (www.fieldcommgroup.org) and FDT Group (www.fdtgroup.org) plans to create one business aimed at advancing integration technology and harmonizing control system applications across multiple protocol topologies supporting process and factory automation. Subject to the completion of a definitive agreement, the new business will continue to support existing FieldComm Group and FDT Group technologies, including Field Device Integration (FDI), Field Device Tool / Device Type Manager (FDT/DTM), Process Automation Device Information Model (PA-DIM), HART and Foundation Fieldbus. FieldComm Group will acquire all FDT technology and resources; an independent Strategic Integration Committee will be formed to guide future directions for protocol-independent device integration. ce – Edited from an FDT Group press release by WTWH Media. FDT Group is a WTWH Media content partner.

Page 15 has more acquisition news.

tems for red meat, fish, poultry, cheese, pet food, and other food markets.

3/11/24 John Henry Foster Minnesota Inc. a strategic collection of engineers, support and service teams, compressed air experts and automation and robotics solutions provider, acquired HTE Technologies, an automation supplier operating in Kansas, Missouri, and Illinois, to be run as an independent division remaining with headquarters in St. Louis. ce Clint Bundy is managing director, Bundy Group, which helps with mergers, acquisitions and raising capital. Edited by Chris Vavra, Control Engineering senior editor, cvavra@wtwhmedia.com.

May/June 2024

|9

INSIGHTS

TECHNOLOGY UPDATE: CLOUD AND EDGE COMPUTING

Choosing the right computing paradigm for industrial transformation There has been a rapid increase in data volume collected by manufacturers. They are examining the advantages and limitations of cloud and edge computing and the potential benefits of a hybrid approach to optimize operational efficiency and decision-making.

T

Online

u

controleng.com KEYWORDS: Control Engineering, edge computing, cloud computing, rockwell automation, efficiency, hybrid approach, data, cloud and edge See other ways cloud and edge helps manufacturing on the Control Engineering robotics page. https://www.controleng.com/ mechatronics-motion-control/ robotics

he 2023 MLC data mastery and analytics survey found that more than one-third of manufacturers say the volume of data they’re collecting has at least doubled in the last two years and nearly 20% say the amount of data has at least tripled. While this surge of data presents opportunities for manufacturers, it also presents a critical question: where should manufacturers process and analyze this ever-growing volume of information?

Cloud and edge computing are distinct approaches to data processing in the industrial data management landscape. Cloud computing, with its centralized servers and vast storage capacity, offers scalability and accessibility. Edge computing brings processing power closer to the data source, enabling real-time decision-making and low latency. Cloud and edge computing each has advantages and limits. Understanding these nuances help with decisions aligned with industrial digital transformation goals.

Cloud versus edge computing Cloud computing has revolutionized data management by shifting away from on-premises infrastructure. This computing paradigm allows manufacturers to transmit vast amounts of industrial data to information technology (IT) and operational technology (OT) applications through an internet connection, unlocking a range of benefits: • Scalability: Cloud computing offers unparalleled flexibility to adapt to dynamic business needs.

The scalability of cloud services allows organizations to easily adjust computing resources based on fluc-

10 | May/June 2024

tuations in demand. Whether experiencing a sudden surge in data processing requirements or scaling down during periods of reduced activity, cloud platforms provide the agility needed to optimize costs and maintain operational efficiency. This adaptability is particularly beneficial for businesses with varying workloads or evolving data processing demands.

• Cost-effectiveness: A hallmark advantage of cloud computing is cost-effectiveness. By outsourcing the management of software and back-end infrastructure to cloud providers organizations can sidestep the need for dedicated IT personnel and costly hardware investments. This translates to substantial cost savings and a reduction in operational complexities.

• Accessibility: Cloud computing enhances accessibility by enabling seamless data access and collaboration from virtually any location with an internet connection. This flexibility is crucial, allowing teams to work collaboratively and access data in real time, without geographic boundaries. Cloud-based applications facilitate remote work, empowering employees to be productive and make informed decisions regardless of physical location.

In contrast to cloud computing's centralized approach, edge computing embraces a decentralized architecture that processes and stores data closer to its source. Edge computing has gained significant traction in recent years, with Gartner predicting that over 75% of enterprise data will be created and processed outside the data center or cloud in just the next five years. This shift toward the edge offers significant benefits to manufacturers, including: • Reduced latency: A key advantage of edge computing is its ability to reduce latency by processing data at its source. This translates into a significant reduction in network travel time, making it a gamechanger for applications where speed is of the essence.

• Enhanced security: The decentralized nature of edge architecture means that sensitive data is processed and stored locally, minimizing the need for extensive data transfers over networks. Edge computing's localized data processing and storage approach means that sensitive information remains control engineering — www.controleng.com

Hybrid edge-cloud computing Both edge and cloud computing offer unique advantages, however the "best" choice hinges on the specific needs and priorities of manufacturing organizations, which involves careful consideration of factors such as cost, security, latency and the reliability of internet connections.

Industrial leaders may find cloud solutions more advantageous when dealing with applications that demand extensive computational power —Manish Jain, and storage capacity. Large-scale data analytics, Rockwell Automation machine learning and centralized data processing are instances where the scalability and flexibility of cloud infraCloud and edge limits Constant internet structure can shine. Conversely, While cloud and edge computing access isn't always edge computing is the more fitoffer immense potential for businesses, they have challenges. guaranteed in remote ting choice for industrial leaders when real-time processing and Cloud computing’s dependence on locations, factories reduced latency are crucial. Edge connectivity can be a significant hurcomputing is ideal for manufacdle for industrial settings. Constant or situations with turing use cases where split-secinternet access isn't always guaranfluctuating network ond decision-making is critical, teed in remote locations, factories or such as in autonomous robotics, situations with fluctuating network —Achim Thomsen, strength. quality control on the production strength. This can lead to disruptions Rockwell Automation line and equipment monitoring. in operations, delays in decision-making and hinder A hybrid approach combines cloud and edge overall efficiency. The volume of data generated by computing to take advantage of the strengths of industrial processes can make cloud-based processing each. A manufacturer can use edge computing expensive. Constant data flow incurs high costs and for real-time sensor data processing and anomcreates bottlenecks and potential processing delays. aly detection to trigger immediate maintenance Perhaps the most critical limitation of cloud computactions and send non-critical data to the cloud ing for certain applications is its inherent latency. The for long-term storage, analysis and optimizatime it takes for data to travel to the cloud, be protion insights. This hybrid approach empowers cessed and return with instructions can range from manufacturers to seamlessly navigate industriseconds to minutes. This delay is unacceptable for al demands, leveraging the strengths of each to applications demanding real-time responses, such as u optimize operational efficiency, enhance deciautomated industrial processes. In time-sensitive scesion-making processes and ultimately drive innonarios, a minor delay can impact operational efficien• Identify the significant vation. Make informed architectural decisions cy and potentially compromise safety. increase in data early in the process. This includes planning for While edge computing offers solutions to cloud's volume collected by manufacturers and hybrid deployments, considering total cost of limitations, it comes with its own set of considerits impact on data ownership and ensuring alignment with security ations. Managing a vast network of edge devices and processing needs. needs. Such planning helps manufacturers to more sensors distributed across various locations adds sig• Compare the advantages easily determine if cloud computing, edge comnificant complexity to the IT infrastructure. This and limitations of cloud and edge computing in puting or a combination is the best option. ce requires specialized expertise and can strain existing the context of industrial IT resources, especially for smaller organizations. data management.

The additional hardware and software needed • Explain the importance to implement edge computing can also translate to Manish Jain is the product leader for edge analytics of a hybrid approach higher costs compared to traditional cloud-based and AI applications and Achim Thomsen is the direccombining cloud and edge computing to optimize architectures. This can be a barrier for organizations tor of common connected applications both at Rockwell operational efficiency with limited budgets or those hesitant to invest in a Automation. Edited by Tyler Wall, Control Engineerand decision-making in manufacturing. new infrastructure. ing associate editor, twall@wtwhmedia.com. within the confines of the organization, drastically reducing the surface area for potential cyberattacks.

• Improved reliability: Edge computing plays a pivotal role in ensuring the reliability of critical systems. In traditional cloud computing models, disruptions at the central data center can impact the entire system. With edge computing, the decentralized architecture distributes computing power across multiple edge devices, reducing the risk of a single point of failure. A distributed approach enhances system reliability and ensures continuous operation even during network outages or disruptions.

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Learning

Objectives

control engineering — www.controleng.com

May/June 2024

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INSIGHTS

NEWS

Automate 2024 Recap: How to accelerate automation’s benefits uAutomate 2024 in Chicago focused on bringing people and technologies together and making automation better and more focused on process and results. The event, by A3, the Association for Advancing Automation, emphasized improving automation using IIoT, AI, and ML to make better decisions and address workforce shortages. Automation innovation includes having the right strategy, technology and people. Safety and cybersecurity remain major focuses and companies can find the right solutions to problems applying standards lower risk to workers and processes. www.controleng.com/articles/automate-2024-recap-how-to-accelerate-automations-benefits

and resources make open-source more accessible to industry through collaboration, said Matthew Robinson. Video: 3 notes about opensource robotics. www.controleng. com/articles/advance-plant-floorrobotics-three-ways-with-ros-industrial-tools

Adding a second set of blades to this 50-year-old concrete mixer required a lot of thought because many safety solutions weren’t practical or were too expensive, said Jenny Tuertscher, VP of technical safety for Fortress Safety in the presentation “Risk Reduction Is Not Always About Changing Your Control System” at Automate 2024 in Chicago. Courtesy: Chris Vavra, WTWH Media

Gary Cohen, Mark Hoske, Amara Rozgus, Anna Steingraber, Chris Vavra and Tyler Wall are Control Engineering and WTWH Media editorial team members who covered the following at Automate 2024.

ino promoted how open-source technology and platforms can help drive technology and innovation. Arduino touted its industrial line and interoperability benefits. www. controleng.com/articles/arduino-touts-industrial-line-interoperability-at-automate

• Advice to get started with industrial mobile robots: Select, integrate industrial mobile robots, from Dynamic Horizons Automation Solutions. See basic terms. www.controleng.com/articles/advice-to-getstarted-with-industrial-mobile-robots

• How to determine where, when, why of a first robot purchase: Mitsubishi Electric Automation answers questions related to: "Should you install a robot?" www.controleng.com/articles/how-to-determine-wherewhen-why-of-a-first-robot-purchase

• How to transform manufacturing four ways with AI: Artificial intelligence (AI) helps engineering, data analysis, programming, troubleshooting in manufacturing, said Microsoft and OPC Foundation. www.controleng.com/articles/how-to-transform-manufacturing-four-ways-with-ai

• How to get more from automation with AI, digital threads: End-users, system integrators and original equipment manufacturers should expect more from automation, said Siemens. www.controleng.com/articles/how-to-get-more-fromautomation-with-ai-digital-threads

• Arduino touts industrial line, interoperability at Automate: Guneet Bedi of Ardu-

• Advance plant-floor robotics three ways with ROS-Industrial tools: ROS-I tools

12 | May/June 2024

• Humanoid robots help improve automation, narrow labor gaps: www.controleng.com/articles/ how-humanoid-robots-can-help-improve-automation-narrow-labor-gaps • Reducing risks for workers without making major changes: See photo. www.controleng.com/ articles/reducing-risks-for-workerswithout-making-major-changes

• Manufacturing’s long-term future looks bright after rough 2023: www.controleng. com/articles/manufacturings-long-term-future-looks-bright-after-rough-2023 • Four steps to designing for future OT cybersecurity challenges: www.controleng.com/articles/four-steps-to-designing-for-future-ot-cybersecurity-challenges • Automation innovation award winners announced: A3 announced AMD, ECM and GrayMatter Robotics as the winners of the inaugural Automate Innovation Awards. www.controleng.com/articles/automation-innovation-award-winners-announced • VIDEOS with ABB, Arduino, Beckhoff Automation, Bundy Group, DigiKey, Interact Analysis, Raymond Corp., Sick, Unitronics, Wago and Weidmuller. www.controleng. com/articles/automate-2024-video-interview-recap-roundup ce control engineering — www.controleng.com

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INSIGHTS THINK AGAIN

®

PO Box 471, Downers Grove, IL 60515 630-571-4070, Fax 630-214-4504

Content Specialists/Editorial Mark T. Hoske, editor-in-chief 847-830-3215, MHoske@WTWHMedia.com Tyler Wall, Associate Editor, 616-879-9146, TWall@WTWHMedia.com Emily Guenther, Webinar Coordinator eguenther@WTWHMedia.com Amanda Pelliccione, Marketing Research Manager 978-302-3463, APelliccione@WTWHMedia.com Gary Cohen, Senior Editor GCohen@WTWHMedia.com Chris Vavra, Senior Editor CVavra@WTWHMedia.com

Contributing Content Specialists Suzanne Gill, Control Engineering Europe suzanne.gill@imlgroup.co.uk Agata Abramczyk, Control Engineering Poland agata.abramczyk@trademedia.pl Lukáš Smelík, Control Engineering Czech Republic lukas.smelik@trademedia.cz Aileen Jin, Control Engineering China aileenjin@cechina.cn

Editorial Advisory Board

www.controleng.com/EAB Doug Bell, president, InterConnecting Automation, www.interconnectingautomation.com David Bishop, chairman and a founder Matrix Technologies, www.matrixti.com Daniel E. Capano, senior project manager, Gannett Fleming Engineers and Architects, www.gannettfleming.com

Frank Lamb, founder and owner Automation Consulting LLC, www.automationllc.com Joe Martin, president and founder Martin Control Systems, www.martincsi.com Rick Pierro, president and co-founder Superior Controls, www.superiorcontrols.com Eric J. Silverman, PE, PMP, CDT, vice president, senior automation engineer, CDM Smith, www.cdmsmith.com Mark Voigtmann, partner, automation practice lead Faegre Baker Daniels, www.FaegreBD.com

WTWH Media Contributor Guidelines Overview Content For Engineers. WTWH Media focuses on engineers sharing with their peers. We welcome content submissions for all interested parties in engineering. We will use those materials online, on our Website, in print and in newsletters to keep engineers informed about the products, solutions and industry trends. * https://tinyurl.com/ControltEngineeringSubmissions gives an overview of how to submit press releases, products, images and graphics, bylined feature articles, case studies, white papers and other media. * Content should focus on helping engineers solve problems.

Articles that are commercial in nature or that are critical of other products or organizations will be rejected. (Technology discussions and comparative tables may be accepted if nonpromotional and if contributor corroborates information with sources cited.) * If the content meets criteria noted in guidelines, expect to see it first on the website. Content for enewsletters comes from content already available on the website. All content for print also will be online. All content that appears in the print magazine will appear as space permits, and we will indicate in print if more content from that article is available online. * Deadlines for feature articles vary based on where it appears. Print-related content is due at least three months in advance of the publication date. Again, it is best to discuss all feature articles with the content manager prior to submission.

Learn more at: https://tinyurl.com/ControlEngineeringSubmissions

Mark T. Hoske, Control Engineering

Control Engineering, in 70th year, joins WTWH Media WTWH Media LLC acquired CFE Media LLC on May 1 to bring greater engineering resources and opportunities to subscribers.

Control Engineering’s

opportunities to serve subscribers and other stakeholders interested in automation, controls and instrumentation increased as WTWH Media acquired CFE Media LLC for an undisclosed amount on May 1. WTWH stands for willing to work harder.

CFE stands for content for engineers.

“Combined with the recent acquisition of Engineering. com, this partnership adds editorial excellence across critical engineering disciplines, expands audience reach of technical engineers and industry executives, and bolsters WTWH Media’s offerings to support B2B [business to business] marketers in reaching the right audience at the right time,” said WTWH Media.

Teams at Control Engineering and CFE Media look forward to finding ways to expand our educational services to automation, controls and instrumentation subscribers as part of the WTWH Media engineering group, which includes 3DCAD & Digital Manufacturing, Design World Network, Electronics Engineering Network, Fluid Power World, R&D Network and Robotics Network.

Scott McCafferty, co-founder and CEO of WTWH Media said: “We are thrilled to add the CFE Media team and brands to WTWH Media to expand our engineering audience reach and offerings to this growing and critical market. The addition of CFE Media will help WTWH Media provide more relevant and critical news, value-added insights, and skill-developing information to our audience as well

Control Engineering began in September 1954 as part of McGraw-Hill and; 50th anniversary cover shows first cover with key anniversaries.

Courtesy:

Control Engineering

as new branding and demand generation opportunities for our marketing partners.”

Patrick Lynch, CEO of CFE Media, said: “Our optimism for the future has never been stronger. We believe the partnership with WTWH Media will benefit our team, audience, and marketing partners. Together with WTWH Media, we are strategically aligned in building the preeminent data-driven, tech-enabled B2B media platform with a full suite of B2B demand solutions. We are excited to help drive growth across several new brands and strategic initiatives, including Packaging OEM, Automated Warehouse, the Digital Transformation Forum event, and WTWH’s Branded Content Studio.”

Jim Langhenry and Steve Rourke, CFE Media co-founders, added: “Since founding CFE Media in 2010, we have seen Control Engineering, Plant Engineering, Consulting-Specifying Engineer, and Industrial Cybersecurity Pulse grow into the marquee brands in their sectors. We are excited to join the WTWH family, which shares our core values and mission.”

Think again about sharing knowledge as we do so at WTWH Media. www.controleng. com/connect/how-to-contribute ce Mark T. Hoske, editor-in-chief May/June 2024

| 15

2024 WORKFORCE DEVELOPMENT

Results are in:

Control Engineering Career and Salary Survey, 2024 Benefits and salaries increased. Leading automation technologies help resolve economic challenges and workforce shortages.

S

alaries and benefits increased for Control Engineering subscribers responding to the 2024 Control Engineering Career and Salary Survey and Report, while supply chain concerns for manufacturing continued to fall. Salaries increased to an average $114,771 (Figure 1), up from $111,345 among those taking the survey in 2023, about a 3% increase, compared to 7% increase in the 2023 survey. The average of those receiving bonuses increased to $16,125 in 2024 (Figures 2, 3) from $15,929 in 2023. The economy (41%) moved ahead of lack of available skilled workers (33%) as the leading threat to manufacturing business in 2024. Last year, they were tied, given the margin of error. Lack of necessary materials/parts fell significantly to 11% in 2024, down from 30% in

2023. Lack of investments for equipment, software upgrades or replacements was at 10% among concerns, twice the 5% in 2023. Financial compensation has the most impact on job satisfaction at 33% followed by the next six criteria in a statistical tie for second (Figure 6).

gies likely indicate increased interest. Like last year, no technology listed was separated from its neighbor by a percentage greater than the margin of error for the research, at +/-6.7% at 95% confidence in 2024.

These were among other key findings in the research.

Automation resolves challenges What technologies can help in the coming year? (Figure 5) Remote controls and monitoring moved to first from seventh while artificial intelligence and machine learning (AI/ML) moved from to third from eighth. Six automation-related offerings, including those two, were statistically tied for first. Power quality and reliability increased to fifth from 17th. Significant shifts in ranking relative to other technolo-

Anticipated increases Automation, controls and instrumentation help manufacturers operate more efficiently and fill the skills gap, and often those with automation expertise mirror demands for technologies. About twothirds of respondents (66%) expect a base annual salary increase in 2024, comparable to the last two years.

Personal performance increased to tie

Expected change to 2024 base annual salary

Expected change to 2024 bonus compensation

Decrease 3% Increase more than 6%

Stay the same

6% 18%

Increase more than 6% Increase 4% to 6%

6%

31%

Decrease

7%

10%

SALARY Average

$114,771

Minimum

$20,000

Maximum

$360,000

NON-SALARY COMPENSATION

18% 59%

42%

Compensation summary 2024

Average (>200k)

$11,840

Average (>0, <200k)

$16,125

Percentage receiving bonus

Increase 1% to 3%

Increase 4% to 6% Stay the same

Increase 1% to 3%

75%

FIGURE 3: In 2024, the average salary of respondents is $114,771, up from

FIGURE 1: 66% of respondents expect a sal-

FIGURE 2: 31% of respondents expect an

$111,345 in 2023, up from $104,071 in

ary increase in 2024.

increase in 2024 bonuses.

2022. Bonuses increased also.

16 | May/June 2024

control engineering — www.controleng.com

company profits at 51% as the dominant criteria for bonus compensation (Figure 4). In 2023, leading criteria for bonuses were 55% company profitability and 43% personal performance.

48% worked 40 to 44 hours (42% in 2023, 43% in 2022)

Job satisfaction, hours for those working with automation, controls While financial compensation is the highest impact for job satisfaction in 2024, the next six criteria were tied for second: Ability to work from home, flexible work hours, technical challenge, feeling of accomplishment, relationship with colleagues and workload. In 2023, three factors with greatest impact on job satisfaction were technical challenge and financial compensation tied at 30% and feeling of accomplishment was at 25%.

Hours worked trended lower.

What technologies are most likely to help you in the coming year?

18% worked 45 to 49 hours (24% in 2023, 29% in 2022)

PERCENT

TECHNOLOGY

29%

Remote controls, monitoring

13% worked 50 to 54 hours (14% in 2023, 9% in 2022)

28%

Analytics: Data analytics

28%

Artificial intelligence (AI) and machine learning (ML)

3% worked 55 to 59 hours (same in 2023, 2022)

27%

Automation applications/upgrades

25%

Power quality and reliability

25%

Process design, measurements, optimization

23%

Process optimization

19%

Industrial internet of things (IoT), such as more interconnected sensors, monitoring, data collection

18%

Analytics for predictive or prescriptive maintenance

18%

Cloud computing

16%

Industrial communications: faster and easier among devices and systems

15%

Better HMI and SCADA designs

15%

Cybersecurity technologies

15%

Sustainability metrics, measurements and related optimization

14%

Automation: Motion control optimization with advanced actuators, drives

14%

Industrial communications: Wireless networking

14%

Resilient and redundant designs for critical infrastructure

12%

Automation: Robotics, collaborative robotics, mobile robotics

Customer feedback

11%

Advanced integrated industrial safety, fail-safe technologies

Quality metrics

11%

Digital twins and simulation

Company stock performance

8%

Edge computing

Better system integration, information flow

6%

Advanced process controls (APC) optimization

Uptime/downtime

6%

Vision system optimization

Plant or line productivity

2%

Other

11% worked fewer than 40 (9% in 2023, 11% in 2022)

6% worked 60 or more (8% in 2023, 5% in 2022).

Diverse automation helps Control Engineering subscribers develop, integrate and use a wide diversity of controls, automation and instrumentation to create solutions; subscribers selected from among 23 technologies in the question: “What technologies are most likely to help you in the coming year? Check all that apply.” Seven replies were in a statistical dead heat for the top spot (Figure 5).

Criteria for 2024 bonus compensation Company profitability Personal performance New business, sales increase, commission

Product profitability

Reducing plant costs Safety metrics

FIGURE 5: While seven technologies likely

Application of industry standards

to help most tied for first in 2024, power

Energy efficiencies or other sustainability metrics

quality and reliability made the largest gain

Increased line flexibility

since 2023 (10 percentage points), followed by remote controls and monitoring and

IT/OT collaboration

artificial intelligence and machine learning

Other

(four percentage points each).

Not applicable (no bonus received)

0%

10%

20%

30%

40%

50%

60%

FIGURE 4: In 2024, company profits and personal performance were tied as the leading criteria for non-salary compensation; profits lead among 2023 criteria.

control engineering — www.controleng.com

All graphics courtesy: Control Engineering research, WTWH Media

May/June 2024

| 17

2024 WORKFORCE DEVELOPMENT

Compared to last year, the following three made the largest increases: • Power quality and reliability increased to 25% in 2024 from 15% in 2023.

• Remote controls and monitoring increased to 29% from 25% in 2023.

• Artificial intelligence and machine learning (AI/ML) increased to 28% from 24% in 2023.

Twenty-three percentage points separate the top from the bottom technology in 2024, while 13 percentage points separated top from bottom last year, possibly suggesting more focus on particular technologies in the coming year.

Survey methods Research for the 2024 Control Engineer-

ing Career and Salary Report resulted from an emailed survey to subscribers, producing 211 qualified responses from April 17 to May 6, 2024, for a margin of error of +/-6.7% at a 95% confidence level. Survey respondents were invited to anonymously provide their annual compensation information and opinions on the current state of their facilities and industries along with advice for peers. (See next article.)

Engineering salary, bonuses In Figure 1, 42% expect a salary increase of up to 3% in 2024 (45% in 2023 and 2022; 51% in 2021; 52% in 2020; 63% in 2019; 56% in 2018); 18% expect an increase of 4% to 6% or more (19% in 2023; 12% in 2022; 14% in 2021; 18% in 2020; 11% in 2019; 19% in 2018); 6% expect more than 6% increase (7% in 2023; 10% in 2022); 31% expect the same (28% in 2023; 32% in 2022 and 2021; 30% in 2020; 25% in 2019; 23% in

What 3 factors have the greatest impact on your job satisfaction?

Financial compensation Ability to work from home Flexible work hours Technical challenge Feeling of accomplishment Relationship with colleagues Workload Relationship with boss Benefits Job security

2018); and 3% expect a salary decrease (1% in 2023 and 2022; 3% in 2021; 1% in 2020 and 2019; 2% in 2018).

For base salary compensation, the minimum was $20,000 ($22,000 in 2023; $20,000 in 2022; $28,000 in 2021), and the maximum was $360,000, ($300,000 in 2023; $266,700 in 2022 and $250,000 in 2021).

For bonus compensation (Figure 2), 18% expect an 1% to 3% increase (15% in 2023); 6% expect an increase of 4% to 6% (same as 2023); 7% expect an increase greater than 6% (8% in 2023); 59% expect about the same (57% in 2023); and 10% expect less (14% in 2023).

For those receiving bonus compensation (Figure 3), the 2024 average received was $16,125 ($15,929 in 2023, $19,162 in 2022).

The 2024 average across all respondents is $11,840, ($11,518 in 2023). In 2024, 25% received no bonus, (27% in 2023).

Engineering bonus criteria Two leading criteria for non-salary compensation were tied: company profitability at 51% (55% in 2023), and personal performance at 51% (43% in 2023), the largest increase in percentage points from last year); see Figure 4. New business/sales at 17% (23% in 2023); customer feedback at 15% (10% in 2023); quality metrics at 14% (17% in 2023); company stock performance at 10% (13% in 2023) and product profits at 9% (19% in 2023), among other responses.

Company's financial health

Engineering job satisfaction, threats Advancement opportunities Leading factors influencing job satisfacCompany size tion for engineers often are technical chalLeading a team lenge and feeling of accomplishment, except Managing people when financial concerns push compensation Physical or ergonomic environment to the lead. While deaths and disruptions Relationship with subordinates from COVID-19 created many workplace Travel challenges, it showed many organizations Other that working from home and flexible hours 0% 5% 10% 15% 20% 25% 30% 35% were possible for some positions, and highly valued, say some respondents.

FIGURE 6: Top factor for job satisfaction is financial compensation in 2024, followed by six When asked which three factors had criteria in a statistical dead heat for second. Ability to work from home and flexible hours greatest impact on workplace satisfacamong the six made the largest increases from 2023.

Location

Feeling of recognition

18 | May/June 2024

control engineering — www.controleng.com

Online

u

controleng.com For more information, see this article online and download the Control Engineering 2024 Career and Salary Report.

CONSIDER THIS On the next pages, see related articles with advice on: • Advancement skills and advice • Workforce training, mentoring • How technologies help workforce development • STEM skills for staging motion control

What are the 3 biggest threats to manufacturing today?

Economy Lack of available skilled workers Competition Government/political interference

KEYWORDS: 2024 salary survey, career advice

Regulations, codes, standards, etc.

LEARNING OBJECTIVES Learn about trends in salary and benefits from the 2024 Control Engineering Career and Salary Survey.

Energy costs Lack of necessary materials, parts Lack of investments for equipment, software upgrade/replacement Inadequate management

Examine perceived threats to manufacturing and changes from prior years.

Compare and benchmark your career progress with peers in the online version of this study.

Outsourcing, offshoring Taxes, tariffs on products

ONLINE If reading the digital edition, click on the headline to access and download the full 2024 Control Engineering Career and Salary Survey and Report to see the benchmarking tables.

Don't know Lack of investments for workflow, manufacturing design upgrades Downsizing Union pressures, restrictions

www.controleng.com/magazine www.controleng.com/research https://www.controleng.com/system-integration/ workforce-development/#pillar-article-header

Other None

0%

10%

20%

30%

40%

50%

FIGURE 7: Leading perceived threats to manufacturing is the economy, moving up from second in 2023 and third in 2022. Lack of available skilled workers was a solid second, down from the top spot in 2023.

tion, financial compensation at 33% (30% in 2023) was the clear lead. Second place, given the margin of error, was a six-way tie among ability to work from home at 25% (up from 15% in 2023), flexible work hours at 25% (19% in 2023), technical challenge at 23% (30% in 2023), feeling of accomplishment at 20% (25% in 2023), relationship with colleagues at 20% (19% in 2023) and workload 20% (16% in 2023). See Figure 6 for 13 other criteria.

Post-pandemic concerns about available material and parts available continued to decrease as a manufacturing threat: 11% in 2024 (30% in 2023 and 42% in 2022). In addition, lack of available skilled workers, while a solid second among perceived threats, became less of a concern in 2024 at 33% (48% in 2023 and 57% in 2022). See other threats in Figure 7. control engineering — www.controleng.com

Slightly younger engineers Control Engineering research provides demographics as context, and extra figures online provide benchmarking.

Younger subscribers increased and older subscribers decreased in several age groups, a trend that’s reflected in recent www.controleng.com online analytics, as well, as older, more experienced workers retire.

Among those surveyed, 5% are under 30 years of age (2% in 2023; 1% in 2022); 15% at 30 to 39 years of age (9% in 2023; 7% in 2022), 18% at 40 to 49 years of age (15% in 2023; 16% in 2022); 22% at 50 to 59 years of age (29% in 2023; 32% in 2022); and 40% at 60 and older (45% in 2023; 42% in 2022).

Years working for current employer trended downward with 50% at 9 years or less (36% in 2023; 43% in 2022), 23% at 10 to 19 years (29% in 2023; 26% in 2022), 17% at 20 to 29 years (20% in 2023; 18% in 2022)

and 10% at 30 or more years (15% in 2023; 13% in 2022).

Years in current industry trended downward slightly: 14% at 9 or fewer years (9% in 2023); 19% 10 to 19 years (14% in 2023); 20% at 20 to 29 years (24% in 2023); 27% 30 to 39 years (30% in 2023) and 20% 40 years or more (23% in 2023).

Highest level of education completed were: <1% high school diploma (3% in 2023), 2% trade/technical school diploma (4% in 2023), 6% associate degree (8% in 2023), 5% college attendance (10%), 56% had a bachelor’s degree (39% in 2023; 48% in 2022), 24% had a master’s degree (30% in 2023; 23% in 2022), 5% dual bachelor’s degrees (2% in 2023) and 1% a doctoral degree (4% in 2023). ce Mark T. Hoske is editor-in-chief, Control Engineering, WTWH Media, mhoske@wtwhmedia.com. Amanda Pelliccione, marketing research manager, WTWH Media, conducted the research and assembled the related report available online.

May/June 2024

| 19

2024 WORKFORCE DEVELOPMENT

Get engineering salary survey advice about Control Engineering careers Respondents to the 2024 Control Engineering Career and Salary Survey provide advice about skills needed to get ahead and technologies they’ll use.

D

evote more time to improving skills and knowledge and use artificial intelligence (AI) and data analytics to help optimize vast amounts of information from automated operation. These were among advice 2024 Control Engineering Career and Salary Survey and Report. Two write-in questions asked survey respon-

dents for advice. Among survey respondents, 54 offered advice on skills; 38 provided technology-related advice.

Skills needed to get ahead Please provide advice about skills needed to get ahead in your areas of responsibility today, including how and why.

Responses, edited slightly for style follow.

Skills needed to advance Engineering Communication/presentation Project management Computer Team-building System integration Language Marketing/sales Finance/accounting Recruitment Other

Learning and skills development You need to spend more time improving skills and knowledge and not be distracted by games, TV, sports and other things. Buy books and read!

Always look for learning opportunities.

Try to present on the information and skills that you have learned. Teach others when possible.

More financial expertise is needed.

Education via mini-MBAs is helpful. As we advance, we do less of what we were trained to do in a university and more of the strategic and company financial areas.

I have found that a good place to start is having an interest in what you do for a living, without it being all consuming, and finding life balance. Reading and comprehending work-related materials are essential.

With the over-abundance of information out there, it is difficult to navigate. There are so many paths to choose, it becomes challenging to know if you are even on the right path.

Don't know

0%

10%

20%

30%

40%

50%

60%

70%

80%

FIGURE 1: Survey asked: What skills do you or others in your areas of responsibility need to get ahead in their profession today? (Select up to five options.) Top skills to get ahead are engineering skills, communication/presentation skills, project management skills tied for first, considering the margin for error for the study. In 2023, the engineering skills answer lead at 72% with communications and project management tied for second at 62% and 61% respectively. Largest gains in 2024 were communications, project management and computer skills, all up by seven percentage points. Courtesy: Control Engineering research, WTWH Media

20 | May/June 2024

Engineering project management Engineering and project management, conceptualizing an entire project lifecycle and key participants. Collaborate across work groups in different departments.

To ensure timely project completion you need to be able to work with customers and contractors to ensure project goals control engineering — www.controleng.com

are completed in a manner to meet customer expectation and stay within budget.

Learn to manage responsibilities: This goes beyond time management; it’s about only committing to and taking on tasks that you should take on. If someone else can do it or should do it, allocate it.

Engineering communication Develop very good communications skills. Being able to communicate with others and to communicate your project needs and how to implement those needs are crucial to project successes. Proper grammar and spelling are critical. Don't always rely on autocorrect.

Process design, analytics Ensure you have a solid, rigorous process design and data analytics background. These skills are the basis for manufacturing productivity.

We need new data-driven decision-making skills to increase strategic decision-making while aligning operational processes to work with new decision processes.

Controls and IT troubleshooting Troubleshooting communications in networks and controls helps with knowledge and accessing knowledge in the company.

Continuing education relating to IT/ OT remains a large skills gap for more traditional/senior controls technicians.

What technologies will help A question asked about technologies likely to help over the next year and why.

AI, analytics, productivity AI and data analytics are quickly becoming essential to optimize vast amounts of information. Tools like these will help us improve decisions. Apply sound judgment and eliminate AI generated garbage.

AI will become a big tool in the coming year I believe. I just don't know-how or when yet. I am not a big AI proponent control engineering — www.controleng.com

How to advance skills Hands-on experiences Continuing education Being mentored Reading industry publications, sites, email newsletters, digital guides, vendor, research and association sites and materials Networking at conferences, memberships in industry organizations, participation in standards bodies and other industry groups Mentoring others Search engines and online AI Other

0%

20%

40%

60%

80%

FIGURE 2: Best ways to advance skills are hands-on experiences and continuing education, followed by being mentored and industry publications. All options scored 20% or more.

Courtesy: Control Engineering research, WTWH Media

but understand it is here to stay. I see virtual reality (VR) becoming more of a useful tool for performing equipment layouts, power and controls. Getting the bean counters to see spending benefits is hard.

Integrate more AI simply because of the time savings.

Upgrade computer hardware, software and production equipment; Hire more employees.

mation relating to emerging technologies.

Trade publications are a good resource.

Cybersecurity, firewalls, malware and other internet safety-related technologies are what I am most interested in. ce Mark T. Hoske is editor-in-chief, Control Engineering, WTWH Media, mhoske@wtwhmedia.com. Amanda Pelliccione, marketing research manager, WTWH Media, conducted the research and assembled the related online report.

Automation, trends Increased IoT provides exponential growth of feedback-loop optimization and u controleng.com opportunity to streamline new systems of controls while deprecating less beneficial KEYWORDS: 2024 salary survey, career advice methods by removal or derating.

LEARNING OBJECTIVES Learn from automation skills advice provided by More automation and integrating peers taking the 2024 Control Engineering Career operator and user interfaces for process and Salary Survey. improvement will help.

Discern applicable advice from peers about More automation to make and design technologies needed to advance in engineering. products for friendly field commissioning.

CONSIDER THIS Apply wireless sensors that communiWhat automation, controls and instrumentation skills and technologies are adding or mentoring? cate directly to the PLC/DCS controllers.

Know about new and upcoming techONLINE See 2024 salary survey research starting on p. 16. nologies. Find ones that are a good fit and See 2023 salary survey advice. that don’t cost more time and money to www.controleng.com/articles/engineering-relatedimplement. skills-automation-technologies-to-get-aheadin-2023 Look for lesser-known conduits of infor-

Online

May/June 2024

| 21

2024 WORKFORCE DEVELOPMENT

Automation engineer pipeline:

The making of an automation professional Strategic automation engineering professional workforce planning requires developing the necessary talent for current and future needs.

Online

u

controleng.com KEYWORDS: Workforce development, automation engineering LEARNING OBJECTIVES Understand that having diverse background for automation engineers are a necessity and a strength of the discipline.

Learn that there’s a need to advertise automation as a career path to students and young professionals.

Demonstrate the importance of creating mentorships among entry, mid-, and senior-level staff that help guide career development.

CONSIDER THIS How does your company enrich those with automation-related responsibilities?

ONLINE See more in the online version of this article: Another graphic, more on field training and on automation engineering as a career path.

T

he complexity of technologies for industrial control systems is increasing, and operators are becoming more reliant on these systems to efficiently monitor and control the related processes. Securing these industrial control systems in the cyber world also is becoming more challenging and time-consuming. Due to the expanding scope of their work, the technical skills of automation engineers are in higher demand than ever. However, the methods firms use to recruit, train and retain automation engineers are not evolving as quickly as the demand.

One strategy is to create three distinct pathways to becoming an automation professional from the perspectives of an entry-, mid-, and senior-level engineer. Data from a recent survey of automation engineers details how they entered the workforce and their suggestions for developing the future automation workforce.

Meet an entry-level automation engineer, Amal Khan In my final semester of pursuing a degree in chemical engineering, I enrolled in a course called Process Dynamics and Controls. This class departed from my usual curriculum, as it focused specifically on a control system’s basic design, methodology and implementation. It significantly shifted my perspective on my chemical engineering degree and the broader field of process and plant design. In traditional classes, the process is

22 | May/June 2024

assumed to behave at steady state and changes in the process result in a new steady state. However, in process controls, the dynamics of the process’ transition from steady state to transient state were heavily analyzed. This approach introduces more realistic scenarios, requiring students to balance the roles of engineer and operator for the first time.

As I began applying for jobs in instrumentation and controls engineering, I noticed employers primarily sought candidates with backgrounds in electrical or mechanical engineering. However, now, as a junior automation engineer, I see how interdisciplinary the automation field truly is. Entering the field of automation engineering, I was met with a landscape that was expansive, challenging, yet incredibly rewarding.

My initial field training (Figure 1) focused on foundational concepts such as understanding piping and instrumentation diagrams (P&IDs), input/ output (I/O), interlocks, human-machine interface (HMI) graphics, writing specifications and reviewing submittals. Navigating the realm of automation felt like diving into a sea of diverse knowledge, making it a challenge to even take the initial plunge. Fortunately, mentors have played an invaluable role in helping me unravel its complexities and grasp an intricate web of concepts.

Mentorship emerged as a crucial pillar of support during my journey in automation engineering. Learning from experienced mentors and peers has provided invaluable insights into different career paths and possibilities within the field. I’m uncertain about the exact trajectory of my career and enthusiastic about the opportunities for growth and development.

Automation engineering offers a dynamic and ever-evolving environment, where the pursuit of knowledge is not just encouraged but necessary for success. I look forward to embracing the exciting opportunities that await in this constantly evolving field. control engineering — www.controleng.com

Meet a mid-level automation engineer, Giselle Villar My automation journey began six years ago, fresh out of college with a degree in Engineering Science and Mechanics. During my studies, there was one mechanics lab that taught what I would later understand to be automation through basic function-block programming using a programmable circuit board. It was such a small portion of my education, and none of my instructors took the time to explain automation as a potential career path. Consequently, I nearly forgot about it until I found myself in an interview for an automation position almost three years later.

During that interview, two automation engineers provided me with my first real introduction into and appreciation for automation. What enticed me was the extreme variety of the work; I would be doing design and programming, be in the office and the field, collaborate with small and large project groups and no project would ever require the same solution. The automation discipline is the perfect place to satisfy an engineer’s innate desire to solve problems.

Throughout my career, I’ve found several exceptional mentors. Half these mentorships developed through our company’s structured mentoring program, while the other half are with teammates who volunteer time and effort to help me, and other young automation engineers, succeed. These are the people who turn project work into learning opportunities.

In college, there’s an expectation that your employer will teach everything you need to know for your role. However, I quickly realized that this wasn’t always the case upon entering the workforce. Instead, I found that my most memorable and effective training occurred not through coursework, but through hands-on experience in the field. Just two days into my job, I found myself immersed in the startup of a new plant along the local team. That’s where I found myself nearly every day for the next several months.

Seeing the “end product” clarifies prior work.

Because of that experience, I have a better understanding of different design decisions and how the reality of things don’t always align with how you think something should be done. I highly encourage all junior staff to get field experience as early as possible (Figure 2 shows Giselle Villar’s mentee), but know firsthand that it can like drinking from a control engineering — www.controleng.com

fire hose without formal education on instrumentation or controls in school.

Recently, I have transitioned into a role between mentor and mentee. With my own mentors, there has been a shift toward partnership and increased independence. Being just outside the comfort zone helps mid-level engineers develop the technical and interpersonal skills needed for automation.

I actively work with junior engineers to identify areas of improvement in their technical and professional training and connect them with people and resources within the firm so they can build a fulfilling career path. It’s crucial to involve junior staff in meaningful tasks from the outset, as they may lack experience but are eager to contribute and grow.

Meet a senior-level automation engineer, Padraic Gray My first job out of college introduced me to the world of industrial controls. I was hired as a commissioning field engineer for an industrial equipment manufacturer. Much of the equipment I encountered was hydraulically operated with a complex network of actuators, motors, pistons and proportionally controlled pumps. Although my mechanical engineering degree was intended to be used for learning the hydraulic power components of the equipment and ultimately working in the research, design and manufacturing, it was the automation aspect of the equipment that captivated me. Coincidentally, the company had a need to fill. Controls were kept at a theoretical level during my education in a couple controls-relat-

FIGURE 1: Field training is the most valuable form of training for automation engineers, and fostering mentoring relationships across different experience levels is crucial for knowledge exchange and growth.

Courtesy: Giselle Villar, CDM Smith

‘

Being just outside the comfort zone, helps mid-level engineers develop the technical and interpersonal skills needed for automation.

May/June 2024

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2024 WORKFORCE DEVELOPMENT

FIGURE 3: Padraic Gray, one of Giselle Villar’s mentors (shown), played a pivotal role in equipping her with the technical knowledge and confidence needed to assume responsibility for a support contract with a local client. Courtesy: Padraic Gray, CDM Smith

ed classes. Seeing the magic of a controls system work firsthand got me hooked into wanting to learn more and do more. (Figure 3: Padraic Gray is one of Giselle Villar’s mentors.) During my commissioning activities, I extensively collaborated with the automation group within the company. My first exposure to working on the controls systems involved learning how to make small changes to the equipment’s programmable controller and graphic display. My involvement with controls deepened unexpectedly when I found myself required to interface with a plant control system at one of the sites I was working on. As the sole engineer on-site with an anxious customer awaiting results, I learned on the fly to make the system operational.

In many ways, I was fortunate to be in the right place at the right time for finding an opportunity as a controls engineer. First and foremost, I had a strong mentor that was able and willing to teach me the basics. Additionally, due to the urgent need to fill the position and the scarcity of suitable candidates, the company agreed to provide me with advanced training and the opportunity to grow into the role. Automation became my chosen discipline more by chance than by design.

Survey of automation engineers To gain insight into the pathways individuals take to enter the automation career field, we conducted a survey involving over 100 automation engineers at various stages of their careers, with an average of 20 years of experience in automation.

The survey results reveal that our stories are not unique. The survey data and comments illustrate what has worked well for the participants in their careers and what they felt could be improved.

Notably, fewer than half the respondents were aware of a career in automation or pursued a curriculum focused on automation during their college education. Instead, most engineers were introduced to the automation field through career fairs or job search opportunities, rather than actively seeking out positions in automation. Many professionals transitioned into automation after gaining experience in process engineering, environmental engineering and other related fields, where they had opportunities to collaborate with automation engineers. Figure 4 illustrates the experience levels of the surveyed automation engineers, within the

24 | May/June 2024

FIGURE 4: Distribution of college degrees among CDM Smith’s automation engineers shows electrical engineering in the lead. Courtesy: CDM Smith

automation industry and elsewhere.

Background diversity helps The wide variety of educational backgrounds among our surveyed automation engineers underscores the strength of diversity within the profession. Each discipline brings valuable insights and skills to the table, enriching the field of automation engineering in unique ways. Among findings: • Electrical engineering is relevant in automation engineering as motor, signal and wiring knowledge is crucial for interfacing between equipment.

• Mechanical engineering details how the equipment parts work individually and how the components move and behave.

• Computer science and information technology encompasses the behavior of a network, including switches, routers and firewalls.

• Chemical engineering describes the process and aids with plant wide optimization.

Mentoring in a welcoming environment is essential for attracting and retaining new talent in the profession. See more with this article online. ce Padraic Gray, senior automation engineer and automation discipline leader; Amal Khan, automation engineer with an interest in control theory; Giselle Villar, automation engineer with interests in young professional development, all with CDM Smith. Edited by Mark T. Hoske, content manager, Control Engineering, CFE Media and Technology, mhoske@wtwhmedia.com. control engineering — www.controleng.com

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2024 WORKFORCE DEVELOPMENT

How to progress in engineering, automation: 3 phases Mentor automation and controls professionals, share advice.

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controleng.com KEYWORDS: Automation, controls, instrumentation, engineering career development LEARNING OBJECTIVES Understand the three phases of careers in automation, controls and instrumentation careers: Foundation, practice and mastery.

See more examples of how foundation, practice and mastery career phases progress with this article online.

Share questions or reflections about careers in automation, controls and instrumentation.

CONSIDER THIS Need with your automation, instrumentation and controls career? Ask Eric at SilvermanEJ@cdmsmith. com.

ONLINE www.controleng.com/ system-integration/ workforce-development www.cdmsmith.com

hat are the various career stages in automation and engineering, and what does a typical career path look like? See also “Mentoring automation and controls professionals by sharing advice, experiences” in the January/February issue of Control Engineering.

CDM Smith delineates career ladders into foundation, practice and mastery phases. As someone who occupies a senior engineering and managerial role in the latter part of my career, I can fondly look back and reflect on these three phases and their profound impact on my personal growth and development. I’ve come to understand that patience, commitment and consistency were the keys to my success. Each journey will differ.

Foundation phase The foundation phase, or what I like to call the “sponge” phase, is where you should explore every available type of work within your company, building technical and professional skills along the way. For the engineers on my team, this involves gaining exposure to everything we do in automation as designers, programmers, field technicians and consultants.

This phase includes development of career-serving soft skills, such as time management, organization, technical writing and professional communications.

It took several years of trying everything to hone my strengths, which empowered progression.

Practice phase During this phase, the level of responsibility and independence increases, while leveraging strengths and forming a strong professional network. In the

26 | May/June 2024

FIGURE: Three phases of careers in automation, controls and instrumentation careers are foundation, practice and mastery, as explained by Eric J. Silverman, PE, PMP, CDT, vice president, senior au-tomation engineer, CDM Smith. Courtesy: CDM Smith

practice phase, many tasks and as-signments that were once part of entry-level responsibilities are delegated to entry level staff, allowing the opportunity to take on projects to call your own.

During this exciting time, you should be thriving in an environment that fosters growth and further develops strengths and interests. The practice phase adds the role of mentor while continuing as a mentee.

Mastery phase In the mastery phase, you’re recognized as a leader or subject-matter expert, carrying signifi-cant responsibility. People rely on your expertise, and you’re now in a position to more widely mentor and give back to others, helping to shape the next generation of professionals. Embracing change and maintaining a mindset of continuous learning are essential to staying engaged in an industry that has evolved significantly since entering the workforce. Avoiding complacency is key! In my journey, I pursued additional certifications and transitioned into a role managing a team, which opened new doors and opportunities. In addition, I volunteered to lead automation initiatives within my company and contribute to Control Engineering.

Where are you in your career journey? ce Eric J. Silverman, PE, PMP, CDT, is vice president, senior automation engineer, CDM Smith, and a Control Engineering Editorial Advisory Board member.

Edited by Mark T. Hoske, editor-in-chief, Control Engineering, WTWH Media, mhoske@wtwhmedia.com. control engineering — www.controleng.com

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Solving the skills shortage requires an innovative approach New technologies help with challenges and opportunities in the manufacturing workforce, including recruitment and employee retention.

Courtesy: Rockwell Automation

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controleng.com KEYWORDS: Skills shortage, labor shortage, workforce development LEARNING OBJECTIVES Understand the current challenges faced by the manufacturing sector in filling open positions and retaining employees.

Identify the reasons why careers in manufacturing are perceived to offer limited career prospects.

Learn about the projected growth and opportunities in the manufacturing workforce despite existing recruitment difficulties.

CONSIDER THIS Addressing the talent gap in manufacturing could unlock significant growth and innovation in the sector.

hat were once warnings about impending talent shortages in the industrial sector are now real challenges for many companies. In December 2023, U.S. manufacturers had 601,000 open positions, according to the U.S. Bureau of Labor and Statistics. In the National Association of Manufacturer’s latest quarterly survey, more than 7 in 10 manufacturers said the inability to attract and retain employees was one of their biggest challenges.

The changing nature of production is a key contributor to the skill shortage. Shifts to more digitalized and sustainable operations are creating a greater need for workers with specialized skills and knowledge who are in short supply. Experienced workers continue to retire, and not enough people are entering the industrial workforce to replace them.

There isn’t a single issue causing the talent shortage, nor a single solution. Companies need a multifaceted strategy with talent and technology to build, support and empower their workforces.

Tapping multiple talent wells Industry has long relied on colleges and universities to supply new generations of engineers and other talent. But considering how much is changing in industrial operations and in the workforce today, academic institutions could use an assist from industry to help keep the talent pipeline flowing with candidates who want to pursue a career in the sector and have the right skillsets.

While perceptions of manufacturing have improved in recent years, too few people are still viewing it as a preferred career option. About 6 in 10 consumers think manufacturing offers limited career prospects. Companies can change this mindset and

28 | May/June 2024

put more students on the pathway to a career in the sector by promoting the career opportunities that await them and showcasing the innovative work that they can be a part of, from driving digitalization projects using disruptive technologies to helping create cleaner, greener industries. Industry can help colleges and universities by working with them to evolve their programs to address changing talent needs. Examples exist across the country of such collaboration.

At the Purdue Polytechnic Institute, industry advisers and partners have supported the new Smart Learning Factory, which provides high-tech, handson experiences for students to learn about intelligent production operations, and new learning pathways for students, like a major in smart manufacturing industrial informatics. University of Wisconsin-Milwaukee’s Connected Systems Institute (CSI) bolsters the smart manufacturing talent pipeline through education, collaborative research and state-of-the-art lab facilities.

Industry is using new and nontraditional talent sources such as retired military members. The Academy of Advanced Manufacturing is helping upskill U.S. military veterans in just weeks to prepare them for roles in advanced manufacturing. Companies hiring employees from these programs can gain peace of mind by filling key roles and take pride in the fact that they’re providing career opportunities to veterans.

Companies must look inward for ways to develop talent in today’s tight labor market. In the area of sustainability, the number of skilled workers isn’t keeping pace with the rising number of jobs. Manufacturers will need to help upskill current employees who have similar skills or a passion for sustainability.

Digitalization is creating demand across industries for specialists in areas like data and analytics. Beyond hiring for these roles, companies are control engineering — www.controleng.com

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* Patented On-Line Edit Saves Down Time Most studies confirm that on the average, a new HMI installation requires 5 edits in the first three months. EZAutomation/AVG is the only company on this planet that allows on-line edit of the screens without shutting down or disconnecting the HMI. This saves the user thousands of dollars in down time. https://ezautomation.net/ez5uniquefeatures 1. Operator wants to have an analog guage

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EZTouch was introduced in 2001. C-more used the same footprint as EZTouch and violated many of the EZAutomation/AVG copyrights as found by a jury. EZ5 fits into the same panel cutout as CM5. Programming is quite similar and as an incentive to move away from HMIs made in China, to HMIs made in America, EZAutomation is offering FREE program conversion from CM5 or EA9 to EZ5 for orders exceeding $4000.

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also upskilling their existing employees in a variety of ways, from hiring training specialists that can create customized training plans to efforts like the digital academy that PepsiCo created to help employees use data and analytics in their jobs.

Technology as a workforce enabler The digital transformation of industrial operations that’s underway puts new demands on workers, requiring them to learn new technologies and thrive in more data-driven roles. Systems and devices can layer easy-to-use tools and intuitive user experiences over complex technology. These can simplify how workers interact with technologies and help them work efficiently. Smart objects are configured in control system design tools and can significantly ease data management for engineers by organizing data and automatically triggering data collection.

Robot integration solutions can help engineers more easily connect robot and control systems or combine them into one system. This can help accelerate deployments, ease access to analytics and simplify operations. New capabilities that digital transformation makes possible can simplify work for engineers and the end users they serve.

One of those capabilities is a digital twin, or a virtual replica of a physical entity or process. With a digital twin of a machine, engineers can build, test and prove their machine first, before they order parts for it or cut steel. Later, the digital twin can be used to virtually commission the machine to help uncover issues before the machine is built and sent to a customer. Once the machine is operational, the digital twin can be used to detect anomalies and test production changes before they’re physically implemented.

Smart capabilities built into drives provide predictive analytics. The drives can help prevent unplanned downtime by modeling the predicted life of their cooling fans and notifying personnel when a fan reaches a certain percentage of that predicted life. Some industrial control systems have special coding that allows energy data from drives and other devices to be made instantly available. This allows the devices to operate as smart meters, giving users better insights into energy use for sustainability efforts.

Embracing workforce transformation Overcoming today’s widespread skills shortage requires rethinking what work is. By creating more control engineering — www.controleng.com

connected workers, companies can create more empowered workers who can act faster and solve problems in new ways.

Bringing design and development work into the cloud allows engineers to collaborate on projects across offices and time zones. Allowing production operators to connect with remote experts in an augmented reality (AR) environment, they can get help troubleshooting complex issues and do unfamiliar tasks. Technology like a computerized maintenance management system (CMMS) can also help automate maintenance tasks, allowing maintenance teams to work more efficiently and spend less time on tasks, like creating and translating work orders, tracking down operators and digging through filing cabinets.

This transformative moment is also an opportunity for companies to align their priorities with those of their workforce in a way that benefits both sides.

Companies need only look at two topics that go hand in hand: safety and sustainability. Clearly, employees care about their own safety. A majority of employed adults also say they want the companies they work for to invest in sustainability.

Today, technologies like contemporary safety systems can help employees work safely without reducing productivity. Using technologies that reduce risks to employees while also taking steps to minimize their environmental footprint can help companies attract prospective employees — and retain current ones — by showing them that they share the same values and goals. ce

‘

Courtesy: Rockwell Automation

Technologies that reduce risks to employees while minimizing environmental footprint can help companies attract prospective employees and retain current ones.

’

Steve Ludwig is the global strategic marketing manager at Rockwell Automation. Edited by Tyler Wall, associate editor, Control Engineering, WTWH Media, twall@wtwhmedia.com.

May/June 2024

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2024 WORKFORCE DEVELOPMENT

Spectacular performers fly with motion controls, STEM, not CGI Theatrical experts and engineers are required to keep the magic in theatrical productions: Professor and technical director at Northern Illinois University.

T

Tracy Nunnally, MFA, is Northern Illinois University (NIU) professor, technical director, head of design and technology, School of Theatre and Dance. He owns Vertigo, a company that provides automation, motion control and special flying effects.

Courtesy: Mark T. Hoske, Control Engineering

Online

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controleng.com KEYWORDS: Engineering for theater, theatrical motion control LEARNING OBJECTIVES Learn that engineers and engineering-minded creative help is wanted in theatrical applications with knowledge of engineering constraints, safety, physics and solutions.

CONSIDER THIS Theatrical production firms also need engineering help.

ONLINE Longer online version of this article includes many motion control applications, photos, video and links.

hose interested in the mechanical behindthe-scenes magic of theatrical production can earn a good living with strengths in science, technology, engineering and math (STEM) fields, according to Tracy Nunnally, MFA, Northern Illinois University (NIU) professor, technical director, head of design and technology, School of Theatre and Dance. That includes making actors and props fly and delivering a performer on a free-floating zipline from atop an open-air stadium to the stage at more than 50 mph.

Nunnally said it doesn’t feel like work as he brings the visions of theatrical creatives to life with flying rigs, motion controls and automation special effects for theater, concerts and other venues. He has a masters degree in fine arts (MFA), multiple industry-specific certifications, appreciation and common-sense application know-how for math, physics and safety, as he explained at an April 17 STEM Café presentation, “Theatrical Special Effects: Engineering Spectacle.”

Motion controls and rigging Nunnally talked about “How to apply the engineering to get the effect you want,” ranging from manual to automated, including making actors fly without computer-generated imagery (CGI).

Nunnally’s discussion included stories related to his NIU professor/technical director position at NIU School of Theatre and Dance, DeKalb, Illinois, and as owner of Vertigo, one of just a few companies in North America that provides automation, motion control and special flying effects services to theatrical productions. MFA studies can include a specialty in one or more specific areas of fine arts. While Nunnally doesn’t have an engineering degree, he uses math, physics, engineering principals, industry-based certifications and a healthy respect for safety to know when and how to employ

30 | May/June 2024

engineers in his projects, making people, objects and props fly for productions such as Mary Poppins, Peter Pan, Seussical the Musical, The Wizard of Oz, Aladdin, Beauty and the Beast and others.

“Math is an important part of what we do,” saying that he re-read his grade school physics book cover to cover when he began this line of work.

Engineers wanted, safety “I love to assist creative people to bring their visions to life. I think about how to engineer the effect, then work with other experts, including engineers, as needed, to make it happen,” Nunnally said. Many people have specialties in theater, including for lighting, but specialists in rigging and automation are comparatively rare. The help-wanted sign is often flying out front, at the intersection of theater and engineering.

Safety is foremost in any production, and insurance coverages are high to protect performers and those around them. Nunnally works carefully with creatives, talent, underwriters and engineers on risk analysis, risk reduction and associated documentation.

Nunnally is involved in the Entertainment Services and Technology Association (ESTA), a non-profit organization that writes entertainment industry standards for American National Standards Institute (ANSI). Nunnally helps write standards and has two third-party Entertainment Technician Certification Program (ETCP) certificates for specific areas and a third certificate for teaching.

The industry is rapidly changing, with more use of advanced design technologies, simulation software and artificial intelligence, and Nunnally welcome younger outside experts to help apply that knowledge to his work. ce Mark T. Hoske is editor-in-chief, Control Engineering, WTWH Media, mhoske@wtwhmedia.com. control engineering — www.controleng.com

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Control Engineering and Plant Engineering’s annual

System Integrator of the Year Awards Entries are due Friday, August 30

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Who should enter?

If you’re a system integrator with demonstrable industry success, Control Engineering and Plant Engineering urge you to enter the 2025 System Integrator of the Year competition.

Past System Integrator of the Year winners—Class of 2024, Class of 2023, and Class of 2022—are not eligible to enter the 2025 System Integrator of the Year program.

What’s in it for the winners?

2021 System Integrator of the Year 11

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The chosen System Integrator of the Year winners will receive worldwide recognition from Control Engineering and Plant Engineering. The winners also will be featured as the cover story of the Global System Integrator Report, distributed in December 2024.

How will the competition be judged?

Control Engineering and Plant Engineering’s panel of judges will conscientiously evaluate all entries. Three general criteria will be considered for the selection of the System Integrator of the Year: • Business skills • Technical competence • Customer satisfaction

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ANSWERS

TUTORIAL: ADVANCED PROCESS CONTROL

PID spotlight, part 5:

Ed Bullerdiek, process control engineer, retired

What does good and bad controller tuning look like?

See seven take-aways for better PID tuning.

T

here are reportedly some 400 to 500 published loop-tuning methods. Each supposedly provides “ideal” tuning constants. In reality, no process is ideal; the best that any control loop tuning method can do is provide a good starting point. This is not to disparage any loop-tuning method, including those to be discussed later in this series. Each method offers unique insight into proportional-integral-derivative (PID) controller performance, and each has advantages and disadvantages. Knowing each methods and when to use them is an essential skill and will greatly improve loop-tuning results. They will rarely give a final answer.

Control loop tuning is as much art as science; therefore it is in our best interests to build up some intuition about how proportional, integral and derivative work together. You should know what a welltuned PID controller looks like. You also should be able to tell when a controller is not well tuned and, based on the controller’s response, be able to draw some conclusions about what the PID constants ought to look like; that is, to have some intuition about what needs to be changed. This comes down to pattern recognition, which forms the core of the heuristic controller tuning method that will be discussed.

First we need to know what patterns we are looking for. Before we discuss what “good” looks like let’s look at one way to benchmark good controller performance, comparing it against the process response when the controller is turned off. Most loop tuning methods assume that a self-limiting process has deadtime and only one lag, also known as first order plus deadtime (FOPDT). Figure 1 shows a process that has three lags, therefore most tuning methods will give an approximate set of tuning constants.

This isn’t a problem. It only means that you may have to trim the tuning constants using heuristics to get the response you need. Note that open loop control engineering — www.controleng.com

settling time is about 4 minutes. Ideally, once we close the loop (place the controller in Auto) the controller should get the process variable (PV) to match the setpoint (SP) at least as fast, and preferably faster, than the 4-minute open loop settling time.

FIGURE 1: See an openloop response of a selflimiting process to a OP change and a disturbance.

Courtesy: Ed Bullerdiek,

retired control engineer Seven take-aways for better PID tuning Seven reminders to improve PID tuning are: 1. A well-tuned control loop will respond to a SP change faster than open loop.

2. Conversely, a poorly tuned control loop will settle the PV on SP slower than open loop.

3. Too much controller gain, integral, or derivative will cause oscillatory control behavior (swinging) regardless of how the other two tuning constants are set. Getting two out of three right is not good enough.

4. Too little gain or integral will result in sluggish controller response regardless of how the other u controleng.com tuning constants are set.

5. In the limited number of situations where derivKEYWORDS: Proportionalative can help adding derivative permits more aggresintegral-derivative, PID tutorial sive overall tuning, which will improve response to SP LEARNING OBJECTIVES Understand how too much changes and rejection of process disturbances. controller gain, integral, 6. Therefore, it is important to get all three tunor derivative will cause a ing constants correct. controller to swing regardless of how the other two tuning 7. When a tuning constant is set improperly constants are set. there is a unique control loop response. This results CONSIDER THIS in a unique visual signature that you can use to Can you use visual cues identify the incorrect tuning constant. This can be to identify controller performance issues? used to guide our loop tuning efforts using heurisONLINE tic tuning methods. ce

Online

Ed Bullerdiek is a retired control engineer with 37 years of process control experience in petroleum refining and oil production. Edited by Mark T. Hoske, editor-in-chief, Control Engineering.

This 7-page article online links to parts 1-4, and sign up for an Aug. 1 RCEP webcast: How to automate series: The mechanics of loop tuning www.controleng.com/ webcasts

May/June 2024

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ANSWERS

PROGRAMMABLE LOGIC CONTROLLERS (PLCS) Jeff Payne, AutomationDirect

Back to the future of the PLC Programmable logic controllers (PLCs) are not going away any time soon, and improving technologies combined with user demands will continue their evolution as a foundational automation platform.

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lmost 10 years ago, I wrote about the “Future of the PLC” for this publication. Even back then, it was important to mention that programmable logic controller (PLC) technology was mature at nearly 50 years old. A decade later, a fair question is whether today’s PLCs have fully entered senior citizen status, and if future iterations are destined for the grave.

FIGURE 1: Now that contemporary open-source processor platforms are available in industrial-grade form factors, such as the AutomationDirect ProductivityOpen, end users have options for integrating traditional automation methods with more modern IT-based languages. Images courtesy: AutomationDirect

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This discussion is especially relevant considering the rapid—and sometimes seemingly exponential—acceleration in computing hardware, software, intelligent measurement, cloud accessibility and communications connectivity. With these and other advances, information technology (IT) has proliferated steadily into the formerly isolated operational technology (OT) realm.

While the article discussed the dramatically increasing importance of communications and connectivity, it did not specifically include the term “industrial Internet of Things” (IIoT), but today IIoT capabilities are essential for nearly any application.

In light of these developments, here are a few thoughts on what the next decade may hold for PLC evolution and industrial automation applications.

Remaining true to the task The core mission of a PLC remains the same as always: To deliver deterministic control and reliable monitoring of physical field devices, even under challenging operational conditions. This has been achieved using specialized processors, operating systems, and programming environments, built into hardened platforms. Yet economies of scale continue to drive the adoption of mainstream consumer and commercial technologies into the PLC role, wherever it is practical. The “smaller, faster, better” maxim has held true and will continue to do so, but mostly around the faster and better aspects, as the trend to further miniaturization has leveled off over the past decade.

Many benefits of electronic component, processor, and solid-state memory advances—reduced cost, shrinking size, minimized power consumption, and increased capability—have already been incorporated into PLCs and other industrial electronics. While marginal size, cost, and power improvements will continue, the real advances will be around capabilities.

At this point, platform size is largely constrained by the need for physical wiring to interface with control engineering — www.controleng.com

FIGURE 2: Today, even a low-cost PLC automation platform like the AutomationDirect CLICK PLUS is packed with advanced logic capabilities, essential motion control, wired/wireless connectivity, a range of IT/OT communications protocols, and more.

PLC input/output (I/O) modules. Traditional wired I/O remains necessary, but in many cases, the connectivity with field devices is shifting to digital networks and distributed remotely using technologies like IO-Link and wireless.

Multi-core processors incorporated PLC designs now enable deterministic control to be supplemented with extensive additional computational and communication function. For over 20 years, the term programmable automation controller (PAC) has been used loosely to describe an industrial controller with greater capabilities than a classic PLC. While a PAC may have initially seemed like a distinct product compared with a PLC, time has proven that automation engineers are less concerned with the nomenclature and much more interested in performance and available features when specifying industrial automation.

While market offerings range from basic PLCs to complex PACs, the concept of an industrial control platform has largely merged into a continuous spectrum of capabilities. Moving forward, users will be willing to consider most any type of underlying hardware platform or operating system as an automation platform—which may continue to be called a PLC but will actually be so much more— control engineering — www.controleng.com

if it can deliver proven real-time control, while providing other required advanced computing capabilities.

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Reconciling flexibility with consistency Although Windows-based systems dominate the consumer and commercial PC world, and are prominent for the industrial visualization realm, this is not the case for real-time control. PLC/PAC platforms typically run a specialized operating system, although there are some Linux-based options. In very general terms, users must balance their desire for openness— which provides great flexibility and low product costs—with the requirement for industrial-grade reliability historically delivered only by proprietary systems. These proprietary systems also provide a high degree of cybersecurity, albeit primarily through obscurity and to an extent unfamiliarity to hackers.

For many years there has been a trend, or at least great interest, towards more open industrial systems, both in terms of hardware platforms and for programming languages. Some end users have applied generic Raspberry Pi and Arduino hardware to implement automation and data handling projects. Others have avoided experimenting in this way with consumer-grade products due to concerns

controleng.com KEYWORDS: PLC, programmable logic controller LEARNING OBJECTIVES Understand how programmable logic controllers (PLCs) have evolved since 2014 and what their role in automation facilities is now.

Learn how communication protocol advances and artificial intelligence/machine learning (AI/ML) also are changing PLCs. ONLINE See additional PLC stories at https://www.controleng. com/control-systems/ plcs-pacs/ Also: See Jeff Payne’s 2014 article “Future of the PLC” at https://www.controleng.com/ articles/future-of-the-plc/ CONSIDER THIS Where do you see the future of the PLC heading?

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ANSWERS

PROGRAMMABLE LOGIC CONTROLLERS (PLCS)

FIGURE 3: Robotics represents a fast-growing area of industrial design, and the demand for capable automation platforms and associated sensing technologies will increase as users seek to thoroughly integrate robotics into their operations.

about reliability, but now a few versions of these platforms have been hardened into industrial-grade devices (Figure 1). Users are showing great demand for the ability to combine contemporary programming platforms with proven industrial I/O and hardware.

With such a range of hardware options, the next hurdle for openness has been homogenizing the programming environment. Classic PLCs used vendor-specific programming that was difficult to port to other brands. The IEC 61131-3 standard introduced ordered PLC programing languages and data types, but vendor-specific implementations still hampered code portability among brands. Eventually, the CODESYS integrated development environment (IDE) offered a more consistent way to create code using the standard languages to deploy it cross-platform on industrial controllers.

However, none of these initiatives addressed the fact that programmers entering the workforce often preferred to code in more modern IT-based languages such as C++ or Python.

Despite all these efforts heading to openness and modern programming languages, it seems safe to say that classic ladder logic is here to stay for the foreseeable future. Ladder logic enjoys a massive installed base, and it remains a simple coding methodology preferred by many electricians, technicians, and even developers. Its graphical style lends itself to basic troubleshooting and typical

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industrial automation functions, and its widespread familiarity provides other advantages.

Today most hardware platforms support ladder logic—whether proprietary or implemented via another IDE such as CODESYS—and many also allow other types of coding methods, which can be mixed-and-matched as needed. Various coding languages have their own strengths and weaknesses for specific tasks, and most users like to apply their own judgement when choosing the best tool for solving a problem, while balancing flexibility against complexity. An added bonus for users is moving outside of proprietary languages enables them to curate a library of code, which can be deployed on any type of target hardware, minimizing rework.

The main point today and looking ahead is users desire automation platforms offered and backed by trusted and experienced industrial suppliers, with provisions for supporting any type of preferred programming language.

Tying it all together with communications Some of the greatest industrial automation strides over the last decade are associated with communications improvements, leading to a truly connected factory. As with controller hardware and programming, the story has been one of moving away from proprietary implementations and towards a more open offering.

Traditional OT-centric fieldbuses, such as DeviceNet, had long offered the reliability and installation form factors demanded by users. But now wired, and even wireless, Ethernet variants are dominating, with several leading industrial communications protocols available. Physical form factor improvements, such as washdown-rated and connectorized components and power over Ethernet (PoE) now enable Ethernet installations to be suitable for industrial environments.

Certain OT protocols such as EtherNet/IP, PROFINET, and Modbus-TCP are associated with makes and models of field devices, while others are optimized for types of automation tasks (such EtherCAT for motion control). While EtherCAT is not new, the incorporation of this protocol natively into more capable PLCs now means low- and medium-complexity motion applications are can be integrated natively into an automation platform control engineering — www.controleng.com

‘

PLCs will add even better programming

without requiring separate motion controllers.

Ethernet-APL is an OT-optimized media, which makes it easier to deploy wired Ethernet out to field devices. IO-Link is on the rise as a streamlined fieldbus—even for basic discrete automation devices—with fit-for-purpose communications capabilities and intelligence.

Bridging OT to IT to securely enable IIoT applications and data transfer in support of remote visualization and analytics requires a different class of communication protocols. OPC UA and message queuing telemetry transport (MQTT) are dominant in this role. While some of their capabilities overlap, there are optimal use cases for both protocols, and users can choose to implement them simultaneously. Other supporting tools, such as NodeRED, have become favored as a graphical method for processing and pushing data to the cloud for consumption by other applications.

From sensor to controller, to on-premises server, to cloud-based resources, to browser, what does this all mean? In the “old days,” smaller controllers would have a limited feature set, so larger devices or multiple integration layers were required to achieve complete connectivity. Today and into the future, users will want these options available in even very basic and low-cost automation platforms (Figure 2).

AI’s role in the PLC’s future No future-looking industrial autoand connectivity mation article written in 2024 could functions to improve overlook the potential impacts of artificial intelligence (AI) and machine the user experience learning (ML). However, much of the current buzz is around using AI/ML and the speed at in a live “runtime” role to analyze and react to conditions. As an automation which projects can platform, PLCs are not currently ideally be delivered. suited for this task, but some advanced versions may be able to run live AI/ML algorithms in the future.

Instead, PLCs are well placed to act as the field interface for higher-level AI/ML resources, providing users with abundant, responsive and contextualized data. They also can implement actions dictated by algorithms.

On the other hand, generative AI (Gen-AI) is poised to play a bigger role with PLCs in coming years from a code creation standpoint. Development environments with carefully integrated AI support tools could help users—perhaps even relative newcomers to the field—develop useful autou mation logic based on libraries and proven code.

AI, used as a development tool, could help speed Programmable logic development times, improve code reliability and controllers (PLCs) minimize redundant or repetitive labor.

The role of integrated robotics For many years, robotics has largely existed as a specialty subset of automation, requiring custom integration into upstream and downstream systems. This is morphing as robotics in general, and collaborative robotics (cobots) in particular, look to be among the single largest growth areas throughout all industrial automation over the next 5 to 10 years (Figure 3). In a related development, vision systems have advanced tremendously in the past decade, and many are very compatible with robots, allowing easy integration in a host of applications.

Modern automation platforms need to be prepared to keep up with this changing landscape by providing the requisite processing power, programming instructions, and connectivity to seamlessly integrate with robotics and vision. A contemporary PLC with these capabilities located near fieldinstalled robotics offers a distinct advantage as an automation platform.

The future PLC is one piece of an automation platform Over the next decade, PLCs as we know them will certainly not go away, even if they are referred to as PACs, or edge controllers, or automation platforms, or something else. There will be no single controller technology that can fulfill all roles at all price points.

Instead, PLCs will continue to evolve based on available technologies and user demand, just as they have done so for the past five decades. The priority will be delivering real-time control and reliable monitoring, but they will add even better programming and connectivity functions to improve the user experience, and the speed at which projects can be delivered. ce

control engineering — www.controleng.com

’

Insights

u PLCs, now almost senior

Jeff Payne is the director of business development at AutomationDirect. Edited by Chris Vavra, web content manager, WTWH Media, cvavra@wtwhmedia.com.

citizens, evolve amidst rapid technological advancement, incorporating mainstream technologies while enhancing capabilities, connectivity, and real-time control functions.

u Users seek openness

in industrial systems while valuing industrialgrade reliability. As PLC programming languages diversify, classic ladder logic remains prevalent, ensuring simplicity and wide user acceptance.

u Robotics, particularly

collaborative robotics (cobots), and artificial intelligence and machine learning (AI/ML) represent significant growth areas in industrial automation.

PLCs are poised to integrate with these technologies, facilitating seamless automation.

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ANSWERS

POWER QUALITY; MOTORS, DRIVES Lucas Paruch, Yaskawa America Inc.

Power quality, harmonics:

How to select a variable frequency drive (VFD) Part 2: Understand the advantages of 36-pulse input drive topology in mediumvoltage (MV) motor applications, and how medium-voltage VFD design mitigates harmonics and improves power quality.

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umping, compressing, blowing, conveying, extruding and mixing are among most common industrial motor applications using variable frequency drives (VFDs).

Understanding applications and drive design can help mitigate harmonics and power-quality challenges. As explained in part 1, when motors are started across the line on 60Hz utility power, efficient motor operation is limited to a very narrow window around the rated motor operating speed and torque values. Drives allow motors to operate at their optimal efficiency over a wide range of speeds, satisfying a wide range of varying torque requirements, while reducing motor stress and starting inrush current.

FIGURE 1: Six-pulse drive topology for a low-voltage VFD is shown. All images courtesy: Yaskawa

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FIGURE 2: In a low-voltage VFD, an L1-L3 charging DC bus acts like a battery, storing energy until needed by the inverter section.

VFD fundamentals, how a VFD works For every motor, the optimal supply voltage and frequency changes as the speed and torque requirements of the application change. When started across the line, a 460V 60Hz motor can only operate at the utility supplied voltage and frequency.

Drives overcome this limitation by continuously adjusting the output voltage and frequency to match the optimal operating conditions for the application load. Most common low voltage (LV: less than 1000V) drives are comprised of three sections; power flows from left (utility supply) to right (motor) in Figure 1.

The diode bridge converts three-phase utility supply power from alternating current (AC) to direct current (DC).

The DC bus acts as a battery. The bus stores the energy it receives from the diode bridge until that energy is needed by the inverter section.

The inverter IGBTs (insulated-gate bipolar transistors) are switches that turn on and off at a very high rate of speed. By using pulse width modulation (PWM), the drive generates a series of short control engineering — www.controleng.com

FIGURE 4: Three sixpulse current waveforms are graphed: Usual, with reactor and ideal.

FIGURE 3: Non-linear charging current: The first current hump occurs when L1 conducts to L2, the

FIGURE 5: 36-pulse in a

second hump occurs when L1 conducts to L3.

wiring diagram.

pulses and long pulses that, when averaged, are representative of a sine wave voltage waveform.

For more Control Engineering details and diagrams about the basics of medium-voltage drives, see: “How to choose a VFD for medium-voltage motors.” www.controleng.com/articles/ how-to-choose-a-vfd-for-medium-voltage-motors

How non-linear loads create power-quality concerns Power quality concerns arise when non-linear loads are connected to an AC supply.

A load is considered linear when its impedance is constant, and the current waveform follows the sinusoidal supply voltage waveform. An electric resistance heater is an example of a linear load. When supplied by a 60Hz sinusoidal voltage, a resistive heater will draw a 60Hz sinusoidal current. Because the current is purely sinusoidal, linear loads have no high frequency harmonic content, and do not contribute to harmonic voltage distortion.

The diode bridge on a typical low voltage sixpulse drive is a non-linear load because the impedance changes suddenly as the diodes turn on and off. Following Ohm’s Law, if the diodes switch the impedance at frequencies other than 60Hz, the current waveforms drawn from the supply must follow the changing impedance, and therefore, the current no longer follows the three-phase supply voltage.

The resulting non-linear current is non-sinusoidal.

While these bumpy non-linear current waveforms (Figure 4) may appear to be random, Fourier analysis shows that these seemingly irregular waveforms are comprised of a theoretically infinite number of sinusoidal waveforms at odd multiples control engineering — www.controleng.com

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controleng.com

of the fundamental 60Hz supply frequency. These frequences are described as the harmonic frequencies. The “third harmonic” is three times the fundamental, or 180Hz, the “fifth harmonic” is five times the fundamental, or 300Hz, etc.

Ohm’s Law shows that supply voltage drop is a function of current. The high frequency harmonic components of the non-linear current result in non-linear voltage drop, and corresponding distortion of the voltage waveform.

Diode bridge allows current to flow one way Diodes are semiconductor devices that allow current to flow in only one direction. When the forward voltage across each diode is positive, the diode conducts current. When the voltage is not positive, the diode stops conducting and opens the circuit.

In Figure 1, the diodes shown in red will only conduct when the 3-phase L1 voltage is positive, the L3 voltage is negative, and the difference

KEYWORDS: Power quality, medium-voltage drives, variable frequency drives, VFDs LEARNING OBJECTIVES Review variable frequency drive (VFD) fundamentals and how a VFD works on the way to understanding how nonlinear loads create powerquality concerns.

Understand harmonic filtering and how a VFD can help.

Examine medium-voltage 36-pulse drive topology and how it reduces risk of equipment malfunction by reducing harmonic stress.

CONSIDER THIS Are your VFDs mitigating harmonics and improving power quality and lifespan for motors?

ONLINE See part 1 in this series: How to choose a VFD for mediumvoltage motors. www.controleng.com/articles/ how-to-choose-a-vfd-formedium-voltage-motors

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ANSWERS

POWER QUALITY; MOTORS, DRIVES

between the two is greater than the DC bus voltage. At this moment, the charging circuit is simplified to that shown in Figure 2 (the other 4 diodes are not conducting, current flows from L1 to L3).

The diodes are arranged to ensure that, as the 3-phase supply voltages alternate from positive to negative, the potential FIGURE 6: 6-pulse current waveform (3 voltage waveseen at the DC bus termiforms): In the 6-pulse topology, two pulses are gennals is always positive. erated for each of the 3-phase input waveforms. The As load is increased, current waveform on each supply phase resembles the IGBTs will draw the distorted “rabbit ears” waveform. more energy from the bus, which will cause the bus voltage to decrease relative to the supply, and charging current will increase. When loaded, a sixpulse drive will experience six charging pulses in each electrical cycle. The DC bus will charge when:

FIGURE 7: 36-pulse current waveform (18 voltage waveforms): In a 36-pulse topology, two bus charging pulses are generated for each of the 18-phase voltage input waveforms, for a total of 36 pulses per cycle, moving the waveform closer to ideal.

L1-L2 > Vbus, L1-L3 > Vbus L2-L1 > Vbus s, L2-L3 > Vbus L3-L1 > Vbus, L3-L2 > Vbus.

Figure 3 shows the charging current that occurs when the L1 voltage is positive. The first current hump occurs when L1 conducts to L2, the second hump occurs when L1 conducts to L3.

For clarity, only the current influenced by L1 is shown. Including charging current from L2 to L3, and from L3 to L2, a total of six charging events occur in each 60Hz electrical cycle.

This is known as a “6 pulse” drive.

Power quality, harmonics, non-linear loads The application of non-linear loads can cause reliability prob-

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lems in power distribution systems if not properly mitigated.

Adding a large linear load (such as a resistive heater) to a power system will produce a linear voltage drop. The magnitude of the sinusoidal supply voltage will decrease, but the shape remains sinusoidal.

The addition of a non-linear load, with varying non-sinusoidal current demand, will produce a non-sinusoidal voltage drop on the power system, distorting the voltage waveform of the supply. Distortion of the supply voltage impacts every piece of equipment connected to the supply. In particular, line-connected motors depend on a clean sinusoidal source. Distortion of the supply voltage can negatively impact the operating speed and torque characteristics of all line-connected motors on the system, and result in increased motor heating and reduced efficiency.

Non-linear waveforms are comprised of a large number of harmonic frequencies. The more a waveform is distorted, the greater the amplitude of the harmonic frequencies. Harmonic currents do not reach the motor, and they do not contribute to creating mechanical power. Harmonic currents flow between the power source and the drive, increasing the overall current load on the supply, as well as increasing the I2R losses of the supply transformer, and all wiring between the power source and the drive.

IEEE 519 provides a method to quantify the effects of total harmonic distortion (THD) and establishes thresholds of acceptability. THD is defined as the ratio of the root mean square of the harmonic current to the fundamental current. In other words, it is the ratio of the undesirable current (that does no work), to the desired current (that produces mechanical torque).

Where I1 represents the magnitude of current at the fundamental frequency (that is, 60Hz), and In represents the magnitude of the harmonic current at the nth multiple of the fundamental frequency (that is, I3 = 3rd harmonic = 180Hz), it can be seen that reducing the magnitude of the harmonic content has a direct impact on reducing the severity of current and voltage waveform THD.

control engineering — www.controleng.com

Harmonic filtering and how it works Line reactors are commonly used in low-voltage drive applications to smooth the current waveform. A line reactor is a three-phase inductor installed in series between the supply and the drive. Inductors are components that minimize current fluctuation by storing and releasing energy, essentially shaving energy from the peaks to fill the valleys. Reactors are effective at reducing current distortion (and resultant voltage distortion); however, they cannot eliminate harmonic distortion. The filtered waveform more closely represents the ideal sine wave but remains non-linear. When designing line reactors into a drive system, the additional cost, voltage drop, thermal losses, physical size and weight of the reactors must be considered.

Medium-voltage 36-pulse drive topology For large motor applications (more than 250HP), multi-Pulse Medium Voltage drives provide an alternate drive topology that improves power quality by minimizing the impacts of harmonic distortion at its source by preventing the formation of highly distorted current waveforms.

A 36-pulse MV drive uses an isolation transformer with six isolated 3-phase secondaries. Each secondary is phase shifted, creating an 18-phase output waveform. Each phase shifted secondary supplies a drive power cell (each cell with its own 6-pulse bridge as shown in Figure 1).

In the 6-pulse topology, two pulses are generated for each of the 3-phase input waveforms. The current waveform on each supply phase resembles the distorted “rabbit ears” waveform of Figure 6.

The same principle applies in a 36-pulse topology. Two bus charging pulses are generated for each of the 18-phase voltage input waveforms (Figure 7), for a total of 36 pulses per cycle. More pulses per cycle allow current to be conducted more evenly and continuously throughout the electrical cycle. The supply sees the sum of the 36 secondary charging waveforms. When summed, the 36 “rabbit ear” secondary current waveforms create the nearly sinusoidal supply current waveform shown in Figure 8.

The 36-pulse topology effectively makes the overall drive impedance more constant by ensuring that when one diode switches on, the change control engineering — www.controleng.com

in impedance is offset by another diode switching off. The drive load becomes nearly linear, with a nearly-sinusoidal current waveform following the sinusoidal supply voltage.

The measurement of harmonic current distortion provides an objective measure of the relative linearity provided by a 36-pulse system. Without additional filtering or mediation, the percentage of current distortion from a 36-pulse drive can fall well within the limits established by IEEE-519.

FIGURE 8: 36-pulse current waveform (18 voltage waveforms): When summed, the 36 “rabbit ear” secondary current waveforms create the nearly sinusoidal supply current waveform.

Less risk of equipment malfunction, less harmonic stress Medium voltage drives with 36-pulse topology provide all the benefits common to all variable frequency drives, while inherently reducing harmonic stress on the supply, and minimizing the risk of equipment malfunction or damage from harmonic induced voltage distortion.

For high power applications, selecting a 36-pulse drive provides an IEEE 519-compliant solution without the need to purchase and install additional input filtering. Because the impacts of harmonics are cumulative within a facility, considering a multi-pulse drive that is well below distortion limits can help compensate for legacy equipment with marginal harmonic characteristics and improve the overall power quality of the facility. ce

FIGURE 9: 36-pulse drive harmonic distortion and IEEE 519 limits: Without additional filtering or mediation, the percentage of current distortion from a Yaskawa 36-pulse drive falls well within the limits established by IEEE-519.

Lucas Paruch is product manager, medium voltage drives, Yaskawa. Edited by Mark T. Hoske, content manager, Control Engineering, WTWH Media, mhoske@wtwhmedia.com.

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ANSWERS

IT/OT CYBERSECURITY John Clemons, Tim Gellner and Vicky Bruce, Rockwell Automation

Crafting the right IT/OT cybersecurity strategy For information technology/operational technology (IT/OT) network cybersecurity, develop strategy, be proactive.

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he old adage is “crime doesn’t pay.” When that saying originated, no one had ever heard of cybercrime. The truth is, cybercrime often pays big. Cybercrimes are increasing, and cybercrime software is readily available and easy to use. Despite time and money spent on cybersecurity, it seems cybercriminals stay one step ahead.

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controleng.com KEYWORDS: Cybersecurity, IT/OT LEARNING OBJECTIVES Understand why cybercrime is a major problem for society at large and particularly for industrial and manufacturing companies.

Learn what’s needed to take a proactive approach to cybersecurity and learn what steps are needed to develop a good cybersecurity strategy.

ONLINE Read more with this article online. See the three-part series online: IT/OT cybersecurity, part 1: Security challenges, trends and methods that don’t work IT/OT cybersecurity, part 2: Developing a proactive and successful approach IT/OT cybersecurity, part 3: Starting the cybersecurity journey

Target: industrial, manufacturing companies Industrial and manufacturing companies are prime targets for cybercriminals. Many industrial and manufacturing companies are ripe for the picking. Legacy unpatched infrastructure, the use of the Internet of Things (IoT) and industrial Internet of Things (IIoT) platforms, insider threats and a lack of operational technology (OT) skilled resources create significant vulnerabilities for industrial and manufacturing companies. An estimated 60% of industrial and manufacturing companies worldwide experienced a cyberattack in the past three years. Because many, including critical infrastructure, are unprepared for a malicious cyberattack, cybercrime will cost an estimated $10 trillion this year.

Broken IT/OT cybersecurity Information technology (IT)/OT cybersecurity solutions, such as firewalls between the business network and the controls network and leaving an "air gap," do not work. Control systems consume and produce a lot of data that people need. Examples include: • The engineering team sends some new logic that addresses a manufacturing change and helps reduce asset downtime.

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• An update for a possible vulnerability in PDF reader software is sent.

• The research and development people send a new recipe that supports a new product and helps improve overall product quality.

• The IT people send patches for the computer operating systems.

• The IT people send updates to the anti-virus software and send new whitelists.

• The equipment vendor must access the system remotely to help troubleshoot a possible mechanical problem.

• Production data must be analyzed to provide insights into the process and products produced.

There are too many ways in which something or someone can get to the control systems. A more systematic and holistic approach is needed.

Proactive, successful cybersecurity Most industrial companies have more legacy information technology and operational technology (IT/OT) assets than they may even be aware of, and it’s these legacy assets that are the most vulnerable. Most industrial companies tend to defend against the last attack rather than prevent the next one. Create a simple four-step framework: 1. Assess the situation, inventory the IT/OT infrastructure, and analyze any vulnerabilities and risks.

An important part of the assessment is to be aware of current threats against hardware and software assets by taking advantage of cybersecurity advisories that are regularly updated such as those from the Cybersecurity & Infrastructure Security Agency (CISA).

2. Design the cybersecurity to handle the IT/OT landscape and address vulnerabilities and risks.

3. Implement solutions, covering people, processes and technology, with training, and on-going proactive services to ensure everything works well.

4. Monitor the IT/OT infrastructure continually, looking for changes, identifying new vulneracontrol engineering — www.controleng.com

bilities, assessing new risks, upgrading the solutions and looking for threats in real time, able to respond in real time to any conceivable threats.

Vulnerability, risk assessment Performing an in-depth vulnerability and risk assessment is one of the first steps to create a comprehensive overall IT/OT cybersecurity strategy.

Cybercriminals will try everything in their arsenal to breach the security measures, so it’s a must to look at all vulnerabilities and risks for all IT/OT assets.

Companies must be proactive, 4 steps A proactive approach to IT/OT cybersecurity requires looking at the entire attack continuum. The basic framework is simple: Assess, design, implement and monitor. It also must contain specific aspects of a proactive approach looking at before a cyberattack occurs, during a cyberattack and after a cyberattack.

A proactive approach assesses the current situation, identifies the assets that are potentially vulnerable, and takes specific measures to protect those assets. A proactive approach detects and responds to the cyberattack. A proactive approach also responds to the aftermath of the cyberattack and takes specific steps to recover from the cyberattack. Consider four cybersecurity ideas to begin immediate improvements.

1. Perform a vulnerability assessment

A vulnerability assessment finds out what’s out there, especially the unknown components and identify potential vulnerabilities. Vulnerabilities might show up as unsecured network connections, unmanaged switches, unpatched legacy systems, or even business-critical systems that no one knows about that are unmanaged, unpatched, obsolete and vulnerable.

The vulnerability assessment needs to examine OT infrastructure including automation and control systems, network components, switches, routers, hubs and any other components in the OT landscape.

2. Perform a full cyber risk assessment

Next perform a full cyber risk assessment for a comprehensive view of the organization's cyber risks, top to bottom. Include these five steps: 1. Get deeper into the details of the OT landscape and vulnerabilities by looking at specific attack vectors and specific weaknesses.

2. Evaluate the entire risk profile by assessing the potential impact of attacks and prioritizing the risks and vulnerabilities. control engineering — www.controleng.com

3. Re-evaluate the effectiveness of existing cybersecurity protocols and look for areas of weakness and opportunities for improvement.

4. Review the industry standards and regulatory compliance requirements looking for weaknesses and areas for improvement.

5. Implement specific remediation measures targeted at the identified risks and vulnerabilities based on the priorities identified.

FIGURE: Every manufacturing and industrial company is vulnerable to a cyberattack and most aren’t prepared for what will happen if they are attacked. Courtesy: Rockwell Automation

3. Perform a full network assessment

Many companies have OT vulnerabilities such as OT systems that are unpatched, legacy, unsecured or obsolete. The OT network is just as important and just as vulnerable. If a quick vulnerability assessment or a full cyber risk assessment identifies the OT network as a particular source of risks, then u a full network assessment might be in order.

Insights ON IT/OT CYBERSECURITY

4. OT penetration testing

Performing OT penetration testing will test the hard work and reveal which cybersecurity strategies work and which ones don’t. The goal is to execute some ethical hacking along a wide range of attack vectors with the purpose of penetrating the OT environment by simulating real-world attacks, along a wide range of vectors.

With a secured infrastructure and daily vigilance, reduce the risk and impact of cyberattacks.

At the very least, companies need to begin. ce John Clemons is a solutions consultant, LifecycleIQ Services; Tim Gellner is a system integration consultant; Vicky Bruce is global capability manager for network and cybersecurity services; with Rockwell Automation. Edited by Chris Vavra, web content manager, WTWH Media, cvavra@wtwhmedia.com.

u Traditional IT/OT

cybersecurity measures, like firewalls and air gaps, prove ineffective against sophisticated cyber threats in complex control systems. A more holistic and systematic approach is imperative for defense.

u Implementing a

comprehensive cybersecurity strategy involves assessing vulnerabilities, designing solutions, continuous monitoring and real-time threat detection.

u When starting the

cybersecurity journey, companies need to create a full assessment that is an open and honest look at what they do and don’t do well and find solutions.

May/June 2024

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ANSWERS

INDUSTRIAL NETWORKING: MES Christian Berg, Emerson

Picking the right MES or automation solution for a life sciences application Life sciences manufacturers have more automation options than ever, but choosing the right manufacturing execution system (MES) or software-as-a-service (SaaS) solution to streamline and improve operations is not as difficult as it may seem.

T

Online

u

controleng.com KEYWORDS: industrial networks, manufacturing execution system (MES) LEARNING OBJECTIVES Understand the benefits a manufacturing execution system (MES) can bring to a life sciences facility, especially when paired with a distributed control system (DCS).

Understand how softwareas-a-service (SaaS) solutions also can help improve automation processes.

CONSIDER THIS How can an MES or automation solution improve operation for your facilities?

he life sciences industry has evolved over the last decade. Emerging scientific discoveries have led to advancements in therapeutics for targeting specific diseases once considered difficult or impossible to treat. Personalized medicine, including cell and gene therapies, has emerged alongside traditional population-targeted medications that have been a treatment staple for decades.

These changes have introduced many new players in the market, all of whom operate very differently from traditional manufacturers. Often, these manufacturers start small, and they rapidly iterate manufacturing processes to deliver novel products quickly and consistently. As a result, there is an increasing need for life sciences manufacturers to stay flexible and nimble. This requirement, as a result, is changing the way many manufacturers approach automation.

The need for large-scale production of traditional therapies has not gone away, nor have the manufacturers making them stagnated. Supply chain issues during the global pandemic made it clear that safe speed-to-market is of the utmost importance for the large-scale manufacturers producing

44 | May/June 2024

the world’s most critical treatments. Though their approach to automation is more traditional, it is no less important as they strive to shepherd hundreds or thousands of batches quickly and safely through the quality review process.

Because the spectrum of treatment manufacturing types is now so broad, life sciences companies are discovering that a one-size-fits-all approach to automation and operations management is no longer appropriate. Fortunately, today’s forward-thinking automation suppliers offer a range of options to help companies implement automation solutions aligned with their needs. Selecting the right automation technology requires understanding each manufacturer’s unique operations management needs and then aligning those needs to the best technological solutions to help the manufacturer optimize product delivery, quality, safety, and cost.

MES: Reliable repeatability In traditional manufacturing of population-targeted treatments, operations trend toward making the same product many times, with limited to no process changes. The process is often well established and the goal of getting treatments into the hands of patients as quickly and safely as possible is transparent. These large manufacturers are often producing batches of the same therapy hundreds of times per year.

These types of companies typically turn to a manufacturing execution system (MES) that is integrated with a distributed control system (DCS) to orchestrate and document batch process activities. This automated, closed-loop control of a full-scale MES reduces the potential for errors in operation by eliminating as many manual activities as possible.

The most advanced systems — those with native control engineering — www.controleng.com

‘

SaaS can be a simple and scalable way to accelerate digitization and improve product lead-time and quality.

’

DCS integration — can instantiate a batch on the DCS, while maintaining all batch characteristics and critical parameters, all without any operator intervention, reducing the risk of human error. When the MES is integrated and validated, the operator does not need to manually enter or verify individual control parameters, thereby reducing opportunities for errors and increasing operational efficiency.

The batch simply shows up on the operator interface, ready to run.

The system is automated from end-to-end, and batch record review can be simplified to only require examination of exceptions that were recorded during the process. When manufacturers leverage review by exception, they eliminate the time spent inspecting batch records, instead focusing only on the areas where the pre-validated process deviated from normal.

Streamlined nimble SaaS In contrast to large batch facilities, there is still a great deal of human involvement in operations in cell and gene therapy and process development spaces due to smaller production scales and rapid process optimizations.

Moreover, many of the manufacturers operating in the personalized medicine space, such as those making advanced therapy medicinal products, are small companies with limited resources to implement and support automation technologies. Often, these manufacturers do not have a deep bench of information technology experts, nor a wide array of staff experienced in the coding necessary to configure and maintain a full-scale MES. However, these small, nimble manufacturers still need automation features — such as enforced sequence of operations, segregation of duties, and robust data integrity — to help ensure good manufacturing practices (GMP) are followed. Consequently, these manufacturers tend to opt for paper-based doccontrol engineering — www.controleng.com

umentation, or for simplified recipe authoring and FIGURE: Software-as-a-service solutions, like Emerson's execution solutions delivered as software-as-a-service DeltaV Workflow Manage(SaaS). Such solutions are a simple and scalable way to ment, empower operators to accelerate digitization and improve product lead-time quickly create recipe authorand quality, without the need for personnel to have ing workflows without any coding expertise to support the system. These solucoding or IT expertise. tions typically do not support integration with autoCourtesy: Emerson mated process control systems.

With the best solutions, users leverage drag-anddrop recipe authoring elements to create the steps for a new recipe and automate workflows. These dragand-drop elements are predesigned to conform with GMP standards, enabling teams to add new parameters and e-signature requirements to drive quality control, ensure regulatory compliance, and automati- u cally generate reliable batch records (Figure).

Automation, MES

Insights

Starting from the right foundation A right-sized automation solution exists for any life sciences manufacturer, regardless of its operations. To make the right decision, manufacturers should first evaluate their needs to identify whether a full-scale MES solution or a paper-on-glass recipe authoring solution best fits their operations, expertise, and budget. Once that decision has been made, teams can explore their many options, prioritizing systems that are feature-rich, and designed for seamless integration and scalability. This approach will ensure their automation systems serve their needs over the entire product lifecycle, even as they scale and their needs continue to change. ce Christian Berg is an enterprise solutions architect consultant for Emerson. Edited by Chris Vavra, senior editor, WTWH Media, cvavra@wtwhmedia.com.

u The life sciences

industry is undergoing a transformative shift and as a result, automation adaptability is crucial for large-scale traditional manufacturers and smaller, agile players.

u Comprehensive

manufacturing execution systems (MES) with native DCS integration can help streamline processes, reducing errors and enhancing operational efficiency for larger facilities.

u Manufacturers in

personalized medicine often use software-as-a-service (SaaS)-based solutions, emphasizing simplicity and scalability for improved digitization without extensive coding expertise.

May/June 2024

| 45

ANSWERS

INSIDE MACHINES: MECHATRONICS Jeff Johnson, Beckhoff Automation

Make exponential gains now: Automation, I/O, mechatronics A reimagined production line delivers complete flexibility to accommodate simultaneous programming and testing of a broad range of terminal types.

D

eveloping automation, input/output (I/O) systems and mechatronics to help companies rethink what’s possible isn’t enough.

Leading by example with an adaptive automation in-house application can help. Keeping pace with manufacturing growth is a constant challenge for Michael Golz, head of the demo systems department at Beckhoff global headquarters in Verl, Germany. It’s

FIGURE 1: The XPlanar-based floating tile motion control system from Beckhoff Automation is optimized for maximum throughput with seamless control and monitoring. This ensures efficient programming, adjustment, calibration and function testing in Beckhoff’s I/O production. Beckhoff AMI8100 integrated servo drives infeed and eject trays because of compact size, 48 V operation and EtherCAT communications. Images courtesy: Beckhoff

M1 | May/June 2024

important not to get stuck in the status quo for Golz and his team of approximately 40 employees, who build manufacturing equipment, among other tasks.

Goal: Exponential increase In fall 2021, Golz’s team and product management experts reimagined how to perform final inspections of input/output (I/O) components. The goal was to exponentially increase testing capacity in a high-mix low-volume (HMLV) process.

The resulting I/O manufacturing system can program, adjust and test 1,200 terminals per hour (about 10,000 per shift) automatically. This concept depends on PC-based control and many EtherCAT solutions, working in concert with specially developed firmware and test stations. This mix of technologies delivers high speed and throughput as well as flexibility for today and tomorrow.

“On average, a fully tested I/O terminal that is programmed with the appropriate firmware leaves the system every 3 seconds, regardless of the type of terminal and the order in which they are delivered,” Golz said. Currently, the system can program and test roughly 80% of many terminal types. The product mix present in the system at any time has zero impact on the line’s throughput... that’s huge, he suggested. Considering the variety of terminals — with or without field programmable gate arrays (FPGA), a controller, or with analog channels — the programming and subsequent function testing of each terminal require different amounts of time.

“It can take up to 30 seconds for the firmware to be installed and all analog channels to be adjusted,” said Stefan Engelke, whose team developed the universal test cabinets.

Complete freedom in motion available delivered the necessary flexibility for internal logistics and infeed of the terminals to the workstations. As a result, it no longer matters whether a bus terminal needs to spend 10 seconds or 1 minute at a firmware programcontrol engineering — www.controleng.com

FIGURE 2: The programming and test times for an I/O terminal have not changed, but the throughput has, significantly: a programmed and extensively tested terminal leaves the system every three seconds.

ming or testing station. The remaining movers go to the next free station rather than idling. Individual delays don’t affect overall system output.

Flexible and transparent The process begins when trays carrying I/O terminals move from the infeed station into the picking station. A delta robot lifts the terminals and places them on waiting movers. The system has two main paths leading left and right to the programming and testing stations. Stations are located at “parking spaces” along the lanes. Between lanes, movers return to the picker on a third path. With this symmetrical setup, one side of the system can continue to operate even if the other stops. Movers pass the terminals under a reading station to the lateral programming stations. The reading station captures the individual Beckhoff Identification Code (BIC) of each terminal via multiple company vision hardware and software technologies.

“After that, the system knows the terminal type and does everything completely autonomously – programming, adjusting the analog channels if necessary and function testing,” said Ulrich Brockhaus, who is responsible for system programming.

At the same time, the BIC is “married” to the mover via its ID. The mover ID also can be used to track the location of each individual mover or terminal, even after a power failure. When the mover reaches a free programming station, it positions the terminal precisely under its contact pins. Then, the corresponding firmware is loaded onto the terminal based on its BIC. It then moves to a universal testing station, which in turn calls up the device-specific test sequence based on the BIC. If the software has been loaded correctly and the function test reports no issues, the mover transports the terminal to the picking station's second delta robot, which places the terminal on another tray, via the middle track. The control engineering — www.controleng.com

FIGURE 3: The bridge with the vision systems which is positioned over the three lanes captures the DataMatrix code of each terminal as it passes through, which is then “married” to the ID of the XPlanar mover.

mover passes through the reading station a second time, only this time in the opposite direction.

“The terminal is booked out via the renewed capture of the BIC on the return track,” Engelke said. “The installation of the firmware and the function test of each individual terminal are documented in the central database, including all adjustment values in the case of analog terminals.”

Online

Tile-based motion control u controleng.com A system consisting of 100 tiles forms the base of this fast, flexible process. The two main paths with KEYWORDS: mechatronics, two outbound lanes and the return track in the midmotion control dle from six base sets of planar tiles with contactless LEARNING OBJECTIVES Understand the capabilities movers, each containing 3 by 4 tiles, Golz said. For of new mechatronics the add-ons (programmer and tester), the remaining technologies.

28 tiles are screwed onto the side of the basic system.

Explore the machine design Each mounting position has a standardized interface possibilities made available by 6D of freedom in motion with power supply (400 Vac), safety, Ethernet local control. area network (LAN), as well as EtherCAT. Prepare for adaptive “The interface and the system layout enable manufacturing concepts future expansions without major conversion that will enable mass customization, high-mix lowwork,” said Daniel Golz, who is responsible for the volume production and other mechanical design of the system and the specific capabilities. details for terminal contacting.

ONLINE The floating planar motion control system enables Further information: www.beckhoff.com/xplanar highly modular machines while simplifying mechanCONSIDER THIS ics in many sectors. For example, the programming How can mechatronics and stations use XY precision positioning. As a result, motion control help your programmers can lower their pins after reaching the operations?

May/June 2024

| M2

ANSWERS

INSIDE MACHINES: MECHATRONICS

FIGURE 4: The positions of the 33 movers hovering over a total of 100 Beckhoff XPlanar tiles are displayed in real time in the visualization created with Beckhoff TwinCAT HMI.

exact position onto the terminal contacts and start loading the firmware.

At the test stations, another feature reduces the design work: the variable flight height. When it arrives at the test station, the mover lifts first so that the slide-in unit of the test station can move under the terminal. Then the mover lowers its hovering height again, so the terminal comes to rest on the slide-in unit and is drawn into the tester. As such, all contacts are freely accessible and can be contacted. After the test, the terminal returns to the mover in reverse order. The option to rotate the movers comes into play again during insertion and removal. Movers can rotate by 180 degrees, depending on the side of the system used.

Four contactless motion benefits “This feature has also significantly reduced the mechanical complexity and has made space-saving configuration of the tester and programmer on both sides possible,” Daniel Golz said.

The system layout benefits from four properties:

FIGURE 5: Electric cylinders help insert the terminal carrier, and linear actuators lower the contact pins.

M3 | May/June 2024

1. The 2D product movements individualize

transport of the terminals and facilitate parallel processing in the programming and testing stations.

2. XY precision positioning means there is no need for a handling system at the programming stations.

3. The transfer of the bus terminals with the aid of the Z movement (lifting/lowering) replaces complex mechanics in the test stations.

4. 360-degree rotation enables the mirrorsymmetrical set-up of the system.

Electrical, optical, control functions The testing stations don’t just check the electrical properties and functions of a terminal.

“For terminals with analog signals, the corresponding test sequences and calibrations are included too,” Engelke said. An integrated vision system checks that the prism is present and in the correct position and measures the colors and intensity of the LEDs in the terminals. A very wide range of EtherCAT terminals, with diverse functions and measuring ranges, can be tested automatically on the system using the universal test cabinet. Its complete measurement and testing system is focused on precise measurement terminals. Mounted in mobile cabinets and coupled to the system by means of a plug connector, the test cabinets can be replaced quickly, without shutting down the entire system.

This needs to be performed regularly, since the terminals are measurement devices which must be recalibrated and certified in specific cycles.

The strengths of PC-based control are evident in the overall coordination and evaluation. If a tester detects a discrepancy on a terminal, this is registered via the BIC while the tester sends the terminal back to the programming stations for reconfiguration. If error messages accumulate on a programmer or tester, this indicates a malfunction.

“In this case, the tester is reported to the system as unavailable,” Brockhaus said. “This position is no longer approached by the movers until the tester has been examined and, if necessary, replaced.”

Although the system will operate with one less station, it’s still up and running and not significantly slower. “An I/O terminal that could cause any problems for a customer would not leave our system,” said Michael Golz. control engineering — www.controleng.com

The system shows how PC-based control can perform a wide variety of tasks and functions. The control cabinet industrial server coordinates 33 movers on 100 tiles; 10 ultra-compact Industrial PCs control the other system components.

Drive technology for the delta robots is handled with the multi-axis servo system and servomotors.

The design uses “integrated servo drives to infeed and eject the trays because they are extremely compact and only require EtherCAT and 48 V to operate,” Brockhaus said.

Linear actuators are used by the programmers to contact the terminals, and the testers use electric cylinders to feed in the terminal carriers. All machine safety technology is implemented with a system that integrates safe ty technology into the EtherCAT I/O system. EtherCAT measurement terminals are installed in each of the four test cabinets.

“Our I/O terminal portfolio offers a wealth of functionality, from 2-channel digital input terminals to compact drive technology, with differing levels of complexity,” said Michael Klasmeier, head of I/O pro-

duction at Beckhoff. “These are produced in annual quantities ranging from a few thousand to hundreds of thousands of units. Our objective is to increase production output with our current employee numbers and in the space available, which would be impossible without automated testing.” ce

FIGURE 7: Most system elements and the mobile test cabinets are built from Beckhoff portfolio components.

Jeff Johnson, mechatronics product manager, Beckhoff Automation LLC. Edited by Chris Vavra, senior editor, WTWH Media, cvavra@wtwhmedia.com.

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Engineering innovation plays a vital role in the vitality of industrial manufacturing.

You’re invited to explore the profiles on the following pages and celebrate the success stories of our participating manufacturing innovators:

• Actemium

• Endress + Hauser Inc.

• Adaptive Resources

• Matrix Technologies, Inc.

• AutomationDirect

• Motion

• Beckhoff Automation LLC

• SEW Eurodrive Inc.

• Digi-Key Electronics

• Skkynet Cloud Systems

• E Tech Group

• Trihedral Engineering

ce2024_innovIND_LEADHalf.indd 1

5/22/2024 4:40:08 PM

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Actemium - Your DX Guide

Digital Transformation (DX) is a substantial manufacturing mountain to conquer. The course you choose has a lot of possible paths and many have tried and failed along the way to reach the summit. When undertaking a journey as critical as this one, it’s important to engage a guide that’s been there and understands how to get to the top successfully.

Actemium is the top guide in the Operational Technology space to navigate your DX undertaking.

Our DX and OT upgrade path includes critical components such as: • Plan the route – Setting an OT roadmap for the next 3 to 5 years to phase in the priorities of DX at the right pace for your people • Make sure your old gear is solid – Have an obsolescence and upgrade strategy that capitalizes on the technology of the future • Leverage new gear to reach new heights – Implement new layers of technology (MES, DataOPs, SCADA) to address gaps in your existing landscape • Use your GPS – Harnessing the insight and power of operational and process data by leveraging AI/ML to drive improvements on efficiency and productivity • Keep your team healthy – Addressing the operational and technology resource challenges that manufacturers face (24x7 support, education of their people, augmentation of key functions)

If you are considering starting, or are in the middle of, your DX assent please reach out and find out the difference Actemium can make in your summit pursuit.

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Contact: Wilfred Misener, Director of Business Development, North America Wilfred.misener@actemium.com Phone: (902) 293-4393

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Adaptive Resources — Industrial Automation Experts

Powerful but Accessible Multi-Variate Control QuickStudy APC is Adaptive’s proprietary Windows® based Control Software that is simple to implement and easy to support. QuickStudy creates process models quickly and accurately by studying your existing process as it operates.

It doesn’t need costly step tests, long set- up times or highlevel expertise. The result is improvements in productivity, efficiency and quality.

Multi-Variate Model Predictive Batch Control QuickBatch APC is Adaptive’s proprietary Windows® based Control Software that is a multi-variate based closed- loop, model-predictive batch control system. It delivers critical process KPIs, improves product quality, and increases productivity demands. Unique optimization capabilities of QUICKBATCH ™ predict end-of-batch quality attributes based on previous end-of-batch processing results.

QuickStudy™ Advantages:

QuickBatch™ Advantages:

• Reduces process variability, improving product quality and consistency.

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• Allows lines to be run at higher rates, increasing throughput.

• Tighter control of process decreases raw materials and energy used.

• Increase product quality on existing equipment, increasing profits and reducing capital expenditures.

• Improve plant safety as process variability is reduced resulting in fewer alarm trips, equipment adjustments and shut-downs.

• Enables Sustainability objectives to be achieved.

• Initially creates a “Golden Profile” based on historical process data. Once this profile has been established, it automatically manages the within-a-batch dynamics in a closed-loop control manner by implementing self-correcting methods throughout critical points in the batch trajectory in order to arrive at the desired end-of-batch required metrics.

• Takes into account both quality and productivity metrics simultaneously in its decision making process to determine the best controller actions to facilitate.

• Effectively addresses complex multivariate based interactions and interdependencies that take place within a batch.

• Once previous end-of-batch results are realized, establishes optimized process settings to eliminate any drifts in end-ofbatch results; corrective measures can also be taken before the next batch is completed.

Ask us about past projects and case studies. www.adaptiveresources.com

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AutomationDirect The company provides online tutorial videos through their web store at www.automationdirect.com as well as their YouTube channel. They also provide FREE online PLC training to anyone interested in learning about industrial controls. A Customer Forum utilized by tens of thousands of automation professionals provides peer support on technical and application questions.

Company headquarters located just north of Atlanta, GA

A well-recognized name in the industrial automation market, AutomationDirect provides quality products with FREE award-winning in-house sales and technical support. AutomationDirect provides customers with quick order and delivery through an online store and toll-free number. Prices on most products are well below the industry average and a 45-day money-back guarantee is offered on nearly all items.

AutomationDirect’s customer support team has been rated top-notch by its customers and has received numerous industry accolades/awards for providing the best service and support on various products. To ensure their service and support remains superior, they continuously survey customers and have consistently outranked other suppliers.

With more than 40,000-part listings, new products include Endress+Hauser pressure transmitters, Metal Work valves, WEG Rolled Steel Motors, and ifm efector barcode scanners, cameras and vision sensors. The company also offers the CLICK PLUS PLCs, DURApulse drives, enclosures, circuit protection, cut-to-length cable, pneumatic supplies and more.

The state-of-the-art headquarters facility near Atlanta is designed throughout for maximum performance. The majority of items are in-stock and ready for fast shipping; orders over $49 ship for FREE. Some exclusions apply.

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Beckhoff Revolutionizes I/O Manufacturing Systems with XPlanar® At Beckhoff, we develop technologies that help engineering leaders automate what’s next. But it’s not enough to tell others what to do. We want to lead by example. So we’re sharing a look behind the scenes at a recent in-house application using our XPlanar adaptive automation system.

Our product management experts reimagined how we perform final inspections of I/O components. The goal was to exponentially increase testing capacity in a high-mix low-volume (HMLV) process. The resulting I/O manufacturing system can program, adjust and test 1,200 terminals per hour (about 10,000 per shift) fully automatically.

The sophisticated concept depends on our XPlanar, PC-based control and a wide range of EtherCAT solutions, working in concert with specially developed firmware and test stations. This ideal mix of technologies delivers high speed and throughput as well as flexibility for today and tomorrow.

“On average, a fully tested I/O terminal that is programmed with the appropriate firmware leaves the system every 3 seconds, regardless of the type of terminal and the order in which they are delivered,” says Michael Golz, head of the Demo Systems department at Beckhoff global headquarters in Verl, Germany.

Currently, the system can program and test roughly 80% of our many terminal types. The product mix present in the system at any time has zero impact on the line’s throughput. Considering the variety of terminals – with or without FPGA, a controller, or with analog channels – the programming and subsequent function testing of each terminal require different amounts of time.

However, the complete freedom in motion available through the use of XPlanar delivered the necessary LEArn MOrE flexibility for the entire internal logistics and infeed of the terminals to the workstations. As a result, it no longer matters whether a bus terminal needs to spend 10 seconds or 1 minute at a firmware programming or testing station. The remaining movers simply move to the next free station rather than idling in a fixed-pitch queue. So individual delays don’t affect the overall high throughput of the system.

All images are copyright © Beckhoff Automation

(952) 890-0000 | beckhoff.usa@beckhoff.com www.beckhoff.com/xplanar

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DigiKey Streamlines Procurement for Engineers and Designers APIs that enable everything from the initial product discovery right up to quoting and purchasing.

“We have APIs that can also enable features and functions in enterprise resource planning (ERP) platforms that go beyond the purchase point, if necessary,” says Nathan Pray, manager, digital technology office – B2B at DigiKey. By leveraging those specific APIs, buyers can easily see order status, order history and other vital information.

DigiKey’s product distribution center expansion

The benefits of using automation to turbocharge manual, time-intensive and monotonous business processes have been well documented. Companies of all sizes, across all industry sectors, are reaping the rewards of automation and can benefit significantly from these investments.

Engineers and designers operating in the evolving electronics sector are particularly well positioned to benefit from automated business processes. Digital solutions like application programming interfaces (APIs), electronic data interchange (EDI) and punchouts give professionals the tools they need to be able to stay in front of these changes and make good buying decisions.

When engineers have the data, they need to quickly source substitutes and backups such as building resiliency into the actual product design without having to go online to hunt around for those alternatives.

DigiKey has the EDI capabilities that buyers need to work efficiently, quickly and accurately and provides

1-800-344-4539 sales@digikey.com www.digikey.com

“We help automate receiving processes by offering APIs that work with barcodes printed on every DigiKey packing slip, order and individual part,” Pray states.

“Our APIs also help buyers manage product obsolescence and change notifications. It’s about enabling the entire purchasing process from discovery to invoice to help orders flow seamlessly from system-to-system.”

Nathan Pray

manager, digital technology office – B2B at DigiKey

We’re in a period of rapid and disruptive change, and there’s no better time to stop chasing paper trails and reconciling discrepancies. Instead, use DigiKey’s APIs, EDI and other automated tools to create a smooth, streamlined communication channel across all procurement activities.

SCAN THE QR CODE TO LEARN MORE

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Video Game Development Tools Meet Industry 4.0 Manufacturing Resulting in Digital Twin Innovation E Tech Group digital twins: 3D visual representation of actual production equipment on your favorite web browser.

We have all heard the story; embracing Industry 4.0 advancements for the purposes of data-driven decision making is foundational to running the factory of the future. To make this abstract idea a reality, E Tech Group has taken an innovative approach, developing intuitive visual tools called digital twins that deliver surprisingly futuristic capability.

Reaching outside the industry, E Tech Group’s development team consists of software engineers with game development experience alongside manufacturing controls engineers, resulting in a second-to-none digital twin.

E Tech Group’s digital twins are built using Unity, a 3D video game development platform. An unlikely perfect tool for this task, the digital twins resemble a video game of the actual system allowing users to fully move around the virtual representation in realtime. The twin is accessible via web interface. etgmarketing@etechgroup.com 1-855-202-1444 | etechgroup.com

Beyond Real-time Virtual Representation There are so many creative ways to extend digital twin technology.

An additional copy can be created to function using the Unity physics engine to determine the system’s motions based on virtual inputs.

Interesting applications include: • Virtual software commissioning: Stress-test software via digital twin.

• System design: Optimize line layout, equipment selection, production flow virtually.

• Virtual system troubleshooting: View the current state of the line via digital twin.

• Virtual sensors for data collection: Monitor particular parameters via the digital twin, rather than the actual equipment.

• Training simulation: Use the physics engine to drive the twin’s behavior.

• Failure prediction and prevention: Apply machine learning algorithms to model the dataset and predict upcoming points of failure.

As full digitalization of manufacturing occurs, digital twins stand poised to become essential tools throughout the life cycle of a production line.

This technology innovation is just one way E Tech Group remains committed to making manufacturing easier.

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Efficiency and safety with digitalization and IIoT The “digitalized future” is now the “digitalized present.” Companies worldwide understand that digitalization is essential rather than optional.

While the digitalization journey began some time ago, the benefits are now clear with how companies’ products send their variables and information to control and host systems and within their ERP, CRM, and service management systems. The digitalization journey has helped companies laser-focus on end-to-end service and solutions.

According to Jason Pennington, Director of Digital Solutions at Endress+Hauser USA, digitalization has enabled companies to digitally connect products to customers in a way they couldn’t before.

End-user expectations Today, instruments can create necessary items such as help desk tickets by themselves or produce alarms and offer potential solutions. Instruments can now provide a secure means from a remote desktop to a device to solve customer challenges before they even realize they have one.

Also, device technology providers and their reps have the opportunity with IIoT, Endress+Hauser’s Heartbeat Technology, and other remote diagnostics to support end-users throughout a product’s lifecycle.

Now, they can go from being connected to utilizing connectivity to solve challenges or enhance their business goals. While it’s up to companies what they do with technology, today’s systems represent devices’ “connected spirit.”

Endress+Hauser and the industrial sector will continue on the digitalization journey.

The more digitized the industry becomes, the more shared data can assist in creating more reliable, safe, and efficient products and systems.

Info.us.sc@endress.com Tel: +1-888-363-7377 www.us.endress.com

Jason Pennington, director of digital solutions for Endress+Hauser

SCAN THE QR CODE TO LEARN MORE

[ the “digitalized future” is now the “digitalized present” ]

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Problem Solved: How a Fulfillment Center Got Back on Track Fulfillment centers and warehouses use conveyor belts of all sizes, with roller drive belts being one of the most important pieces. Located inside the conveyor and driving the rollers from underneath, these belts are often hard to see and inspect. They must be correctly installed and maintained for optimal reliability and service.

Tracking issues are the leading causes of belt failure; other issues are lack of flexibility and grip, and an unreliable or inefficient splicing system. Addressing the belting issues, Motion Conveyance The Novitool® Aero® 325 press automates the recipe and pressure—all with an 18–22-minute cycle time.

Solutions developed RedDrive® 45 and 77, which feature lowered drive tension—typically reduced by 20–25%, but some cases have neared 50%. For a dependable splicing system, Motion Conveyance Solutions partnered with Flexco to dramatically improve the original manufacturer’s equipment, requiring a cycle time of 45–60 minutes.

The Novitool® Aero® 325 press runs on 110 V power, weighs under 50 lbs and automates the recipe and pressure—all with an 18–22-minute cycle time.

The same team also created the Novitool Pun M ™ NDX ™ belt cutter.

It allows the belt to safely clamp to the cutting deck while the operator turns the handle to auto-index cut the belt end fingers. This design lowers preparation time by 80–90%, improves the belt finger cut quality, reduces operator error and operates considerably safer.

These essential components created a need for the Motion Conveyance Solutions Novitool RedDrive workstation. This unique system holds required splicing equipment and provides belt storage for a streamlined process.

When downtime minutes count, Motion Conveyance Solutions’ roller-driven conveyor belt delivers longer life and a dramatically improved splicing process.

Visit MiConveyanceSolutions.com or scan the QR code to learn more.

Seth Stoner is the Director of Product Management for Motion Conveyance Solutions. He has held many roles in his 28 years in the conveyor belting industry.

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Automation Made Easy with SEW-EURODRIVE More than Just Gearmotors SEW-EURODRIVE offers more than just gearmotors. We also manufacture a full line of automation components, controls, and the software to drive them. Our team of automation experts understands the latest technology and can solve even the most complex motion control challenges.

MOVI-C Modular Automation System A flexible one-software, one-hardware, automation platform that combines fully integrated drive components, control electronics, and automation software – all from a single source. The key to this simple-to-use platform is that each of those components is designed to work together seamlessly, taking the hassle out of machine design, operation, and expansion.

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Eliminate costly power and communication cable runs and save floor space by reducing or eliminating bulky control cabinets. Simplify control functions with motor- and near-motor mounted inverters. To truly future-proof your application, a decentralized system provides the most flexibility for process and configuration changes.

Power and Energy Solutions Reduce power peaks in your supply grid with SEW-EURODRIVE Power and Energy Solutions. As part of the MOVI-C® modular automation system, our power and energy system is suitable for machines and systems that involve dynamic accelerations and decelerations, which waste energy during braking and spike energy during startup. Control cabinet inverters compensate for peaks by temporarily storing the braking energy generated, making the energy available as needed. This technology stabilizes the energy flow and reduces spikes. Using an innovative power and energy management system can boost your system’s energy efficiency and availability.

About SEW-EURODRIVE: Engineering excellence and customer responsiveness distinguish SEW-EURODRIVE, a world leader in drive technology, and a pioneer in drive-based automation.

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Cogent DataHub™ Tunnel/Mirroring solves DCOM security patch issues Cogent DataHub™ technology from Skkynet lets you network OPC DA data using only local OPC connections, and pass the data across the network over TCP, with optional SSL if needed. A DataHub tunnel/mirror avoids DCOM and solves the Microsoft KB5004442 security patch problem.

Microsoft took an important step recently toward keeping industrial systems secure. They made their KB5004442 security patch for DCOM mandatory. This affects all systems that network OPC DA, one of the most widely used industrial protocols in the world. Now all OPC DA systems that use DCOM across a network must use the highest security settings. Any networked connections with lower security settings will fail.

To solve this problem, DataHub tunnel/mirroring makes only local connections to both OPC DA servers and clients. It passes their data across the network over TCP, using SSL if required. Both OPC DA server and client stay connected if the connection goes down, and the client is informed of the break. This approach completely eliminates the need for DCOM.

For moving data beyond the plant network, DataHub tunnel/mirror technology offers a more secure connection than DCOM. You can configure it to make only outbound connections from the OPC server side.

This keeps all inbound firewall ports closed, while still allowing the data to flow one way or both ways.

To connect OT to IT for remote access, DataHub tunnel/mirror technology supports network isolation through a DMZ. By installing a third DataHub instance on the DMZ, each side can make outbound connections through firewalls, and still maintain one-way or two-way data flow.

Whatever your application, there’s no need to view Microsoft’s move to secure DCOM as a problem.

DataHub tunnel/mirror technology offers solutions at any level that are more flexible and more secure than DCOM. Find out more.

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VTScada Receives IEC 62443 - ML 2 Cybersecurity Certification for its Secure Development Lifecycle Process Some of the largest automation systems in the world rely on VTScada software to ensure system uptime.

For this reason, the VTScada development team has always taken great care to provide advanced cyber security features and follow software development best practices. Now, after rigorous evaluation by exida, VTScada has again risen to the high standards required to help keep mission critical infrastructure safe.

VTScada’s Development Environment is now certified to be compliant with IEC 62443 Security for Industrial Automation and Control Systems - Part 4-1: Secure Product Development Lifecycle Requirements for Maturity Level 2.

This standard defines secure development life cycle (SDL) requirements for products used in industrial automation and control systems. This includes security requirement definitions, secure design, secure implementation verification and validation, defect management, patch management, and product end-of-life.

These can be applied to new or existing processes for developing, maintaining, and retiring hardware, software, or firmware. exida is a world leader in product certification specializing in automation system safety, alarm management, cybersecurity, and availability.

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Toll-free: 1-800-463-2783 (North America) Worldwide: 1-902-835-1575 info@trihedral • www.vtscada.com

2024

®

The best automation, control, and instrumentation products, selected by engineers The winners of the 37th annual Control Engineering Product of the Year awards have been chosen, highlighting some of the most notable technologies in the industry. This year, companies submitted their latest and most innovative products, launched between January 1, 2023, and December 31, 2023, to compete for this distinguished honor. Our readers then selected 35 winners, including the 2024 Most Valuable Product, which garnered the highest number of votes overall. Detailed descriptions of the 2024 Control Engineering Product of the Year winners, along with the official rules, are available at: www.controleng.com/events-and-awards/product-of-the-year.

Entries for the 2025 program will open on October 1, 2024, and will include products first introduced to the North American market within the 2024 calendar year.

Amanda Pelliccione is the marketing research manager for WTWH Media and its publications, including Control Engineering.

62 | May/June 2024

control engineering — www.controleng.com

Back to Basics PLC PROGRAMMING

How to reduce workload using reusable components for PLCs Multiple programmable logic controller (PLC) platforms now support pre-packaged code to reduce programming time.

W

riting programmable logic controller (PLC) programs from scratch is usually time-consuming and tedious. Many know about the long-term costs and frustrations of debugging and maintaining code, but a method can increase the code's dependability and quality while streamlining and simplifying the PLC programming process. Multiple PLC platforms can use pre-packaged code to reduce your programming time and support.

Three benefits of pre-packaged code Pre-packaged code is a collection of pre-made libraries and functions that let users quickly construct PLC applications. Pre-packaged code can help users to: 1. Accelerate your code: Using tested pre-packaged code to perform common tasks reduces the time spent writing code.

Due to this, the code may become more responsive, resilient and faster. Users also are minimizing errors by using proven and validated code. This reduces testing and troubleshooting time.

2. Standardize: Pre-packaged code can be used across hardware platforms and projects. Users can use the same functions and libraries for different projects and follow identical coding conventions and best practices. This can make the code more readable, consistent and more accessible for others to support.

3. Reduce support costs: Using pre-packaged code, users can update or replace these packages when needed. For example, if a machine uses pre-packaged code that interacts with an outside platform, users can update the package without redoing the code if it updates its communication spec.

CODESYS is a programming software that works with multiple PLCs. In the CODESYS, pre-packaged code is available in the form of libraries. Users can download free libraries; some have a cost or work with specific hardware. To use pre-packaged code in CODESYS, users need to:

1. Identify the library that contains the code you need.

2. Import the library into your project.

3. Write the code to interact with the library. control engineering — www.controleng.com

FIGURE: The Library Manager in CODESYS that allows users to add and select pre-packaged code for a project.

Courtesy: Vision Control & Automation

There was a case where message queuing telemetry transport (MQTT) messaging to an existing PLC program. CODESYS has several library options, including support for Sparkplug B. For this application, the WagoAppCloud library and its MQTT support were used to send messages to the MQTT broker.

Adding SQL database connectivity is u not a feature that comes with the PLC. controleng.com Multiple libraries can connect to a dataKEYWORDS: PLCs base. A hardware-specific library allows LEARNING OBJECTIVES users to connect and send SQL syntax to Understand what prea database. Using pre-packaged code can packaged code is and how it is used for programmable help reduce programming time and suplogic controllers (PLCs). port efforts and improve workflow and Learn benefits, see development time. Users benefit from the examples. advantages of pre-packaged code and creCONSIDER THIS What applications could ate better PLC programs faster and easier benefit most from this? for the next project. ce

Online

Brandon Teachman is an application engineer at Vision Control & Automation. Edited by Chris Vavra, senior editor, WTWH Media, cvavra@wtwhmedia.com.

ONLINE www.controleng.com/ video/automate-2024interview-brandonteachman-vcawi-on-plcscontrol-systems-andautomation-trends

May/June 2024

| 63

Publication Sales VP, Sales Matt Waddell Sales Account Manager Brian Gross

Advertisers' Index COMPANY

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AutomationDirect . . . . . . . . . . . . . . . . . . . . C2, 1 . . . . . . . . . . . . . . www .automationdirect .com

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Sales Account Manager Dean Morris Sales Account Manager Judy Pinsel

MWaddell@WTWHMedia.com 312-961-6840

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EZAutomation . . . . . . . . . . . . . . . . . . . . . . 32A-32D . . . . . . . . . . . . www .EZAutomation .net MOTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 . . . . . . . . . . . . . . . . www .Motion .com ONLOGIC . . . . . . . . . . . . . . . . . . . . . . . . . . . . .31 . . . . . . . . . . . . . . . www .onlogic .com/tacton SEW-EURODRIVE, Inc . . . . . . . . . . . . . . . . . . C4 . . . . . . . . . . . . . . . www .seweurodrive .com SKKYNET . . . . . . . . . . . . . . . . . . . . . . . . . . . . C3 . . . . . . . . . . . . . . . www .CogentDataHub .com TADIRAN BATTERIES . . . . . . . . . . . . . . . . . . .14 . . . . . . . . . . . . . . . www .tadiranbat .com Trihedral . . . . . . . . . . . . . . . . . . . . . . . . Bellyband, 13 . . . . . . . . . . www .VTScada .com/time VEGA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .25 . . . . . . . . . . . . . . . www .vega .com/radar WAGO Corp . . . . . . . . . . . . . . . . . . . . . . . . . . .27 . . . . . . . . . . . . . . . www .wago .us

MEDIA SHOWCASE FOR ENGINEERS

Publication Services Patrick Lynch, Senior Vice President, Sales & Strategy 847-452-1191, PLynch@WTWHMedia.com McKenzie Burns, Marketing Manager MBurns@WTWHmedia.com Courtney New, Program Manager, Content Studio CNew@WTWHMedia.com Paul Brouch, Operations Manager 708-743-5278, PBrouch@WTWHMedia.com Rick Ellis, Director, Audience Growth 303-246-1250, REllis@WTWHMedia.com Michael Rotz, Print Production Manager 717-422-3622, mike.rotz@frycomm.com Custom reprints, print/electronic: Paul Brouch, PBrouch@WTWHMedia.com Information: For a Media Kit or Editorial Calendar, go to https://www.controleng.com/advertise-with-us.

Letters to the editor: Please e-mail us your opinions to MHoske@WTWHMedia.com. Letters should include name, company, and address, and may be edited.

64 | May/June 2024

control engineering — www.controleng.com

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