Control Engineering 2023 JanFeb by WTWH Media LLC

How to automate, throughout issue, and page 11

Hot topics of 2022: Did you see these? | 22

Programming: Do this, not that | 30

Ethernet help | 32

VFDs 8 tips | 33

| 36

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60 | Compact programmable logic controllers, Client computer-on-modules, Hazardous location linear position sensors , Asset performance management platform, Control panel storage, Remote data-collection module, Power supplies with EtherCAT interface, Environmental monitoring system, PLC edge gateway, Fixed acoustic imager

See more products in every issue. www.controleng.com/NPE.

For the 2023 Control Engineering Product of the Year awards program (formerly known as Engineers' Choice Awards), 74 nominees cover 14 categories. Subscriber voting opened on Feb. 1 and closes on March 14. The ballot will be accessible via www.controleng.com/eventsand-awards/product-of-the-year and hosted in Alchemer (formerly SurveyGizmo). Winners will be featured in the next version of the Product of the Year eBook on Thursday, June 1, 2023.

Back to Basics

63 | Connecting legacy equipment

New and old equipment can work together seamlessly when industrial PCs (IPCs) come into the picture.

NEWSLETTER: Mechatronics and Motion Control

• Three motion control trends for 2023

• Hot topics in Control Engineering for 2022

• Product advice: Smart mechatronics platforms offer new handling solutions

• Cameras give industrial vision-guided robots human-like functions

• Analysis: Ability to delay Microsoft DCOM hardening patch ends as of March 2023.

Keep up with emerging trends: subscribe. www.controleng.com/newsletters.

JANUARY/FEBRUARY 2023

u Control Engineering eBook series: Robotics Winter Edition

Robotics are one of the fastest-growing industries, and their impact can be felt on many manufacturing floors. There’s more to the robot, however, than what you see on the plant floor. Featured articles include stories on assembler robot groups, soft robots and robot integration. Learn more at www.controleng.com/ebooks

u Global System Integrator Report

Learn more at http://tiny.cc/M2E2023

Do you market to engineers or know someone who does? Marketing to Engineers, May 3, 2023, in Chicago.

Supplement to November/ December Control Engineering and Plant Engineering includes System Integrator of the Year, System Integrator Giants, application stories. www.controleng.com/ magazine

u Control Engineering digital edition

The tablet and digital editions provide links to additional article images and text online and links to other related, useful resources.

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5 FAST FACTS on exclusive Control Engineering research: How to apply controllers

u FIVE FAST FACTS about Control Engineering research on how to apply controllers follow. Answers below allowed for more than one reply. The research, conducted in January 2023 with subscribers who specify or purchase, integrate, use, maintain or upgrade controllers for industrial applications, has a margin of error at 95% confidence, of +/-8.5% to +/-8.8%, depending on response rate for various questions. Responses totaled 134. More results will be posted online at www.controleng.com/research.

1. Top five controllers purchased in last six months were 73% programmable logic controllers (PLC), 61% human machine interface (HMI) hardware, 41% industrial PCs (IPCs), 32% drives for motion control and 31% programmable automation computers.

2. Five areas where those industrial controllers were applied or use in last six months: 63% distributed on plant floor o r near application, 57% on machines, 34% embedded in machines, 15% virtually in a server away from the application and 13% virtually in a server locally.

3. Who’s implementing the controllers is evenly split (within margin of error) between 63% end-user automation, controls or instrumentation team members and 57% system integrators. Others applying include 27% other end-user engineering or technical staff, 23% consultants, 14% other contractors and 7% other.

4. Types of applications in the last six months were evenly split (within margin of error) among 57% continuous process control, 57% machine control and 54% HMI development. Others were 49% alarming, 40% monitoring, 40% supervisory control and data acquisition (SCADA), 37% programming/test applications, 37% remote monitoring, 36% diagnostics and 35% safety. (See more online.)

5. How are controllers and programming being applied: Top 5 ways are 49% software tested offline, installed in controllers, which are then installed; 46% new hardware and software programming tested offline and networked to the new application; 42% new hardware and software programming tested offline and connected via local port via to a computer with the new application; 37% new hardware and software programming tested offline and brought on USB via connected computer to the new application; and 19% new software programming tested in simulated digital twin of application .

Other areas of the research, covered more in the online article and in the March issue include: Controller communications hardware and numbers of protocols needed, where controllers communicate, opinions on applying industrial controllers, cybersecurity, integration of software and hardware, upcoming purchases and if there are any vendor or controller-type restrictions. ce

Amanda McLeman is CFE Media and Technology research director, Mark T. Hoske is Control Engineering content manager, mhoske@cfemedia.

Leveraging real-time data across the enterprise

u COMPANIES want to bring systems into the modern age and obtain real-time manufacturing data at the machine level without manual intervention. They want to bring everyone onto the same system and reduce training and licensing costs. Companies want better control and efficiency in day-to-day operations. And they want to scale business to meet aggressive expansion goals. A system integrator conducted a needs analysis and executed a plan for a packaging company that serves end users in the pharmaceutical industry. Click the headline in the digital edition for more. ce

SIMPLIFYING the MES system stacking can make communication simpler and easier. The Sepasoft business connector connectivity tool works with the SAP ERP module for native connection to SAP servers and uses the SAP remote function call (RFC) protocol without additional middleware. Courtesy: Grantek/Sepasoft

System integration, edge computing tips for automation

System integrators are using edge computing platforms to create simple, scalable, repeatable and protected automation and control architectures. Jan. 25 webcast, archived for a year, offered tips and other information.

Edge-computing-based automation across multiple locations was discussed in a Jan. 25, webcast, archived for a year, “Tips on achieving scalable, repeatable, and protected automation solutions.” With digitalization comes an edge-computing-based approach for automation and control architectures. As system integrators search for better ways to create simple, scalable, repeatable, and protected solutions for customers, edge computing platforms can help. An industrial automation edge computing use case shows how a system integrator delivered a multi-site automation and control solution efficiently, securely and at a competitive cost while providing the customer with a robust and reliable system.

According to Mike Bradshaw, senior director global channels and partner ecosystem, Stratus Technologies, and Sam Chumbley, vice president of business development, Flexware Innovation Inc., edge computing:

• Consolidates and modernizes automation and control systems that help integrate human-machine interface and supervisory control and data acquisition (HMI/SCADA) software with other automation such as historians, manufacturing execution systems, batch software, analytics and cybersecurity.

• Resolves challenges associated with automation and controls, as customer case studies show.

• Can be implemented in automation solutions across multiple locations, with appropriate services after deployment.

One application Chumbley discussed includes an edge computing server running six virtual machines, more than 10 programmable logic controllers (PLCs), more than 10 thin clients (including smartphones and tablets), badge readers, remote view-only monitoring, and a message queuing telemetry transport (MQTT) distributor for

logging data to an enterprise portable for key-performance indicator information. The mission-critical application, with “nearly zero” IT support at each site, cannot have downtime; operator training is critical for reliable operations and compliance with regulatory requirements.

Bradshaw said ways to prevent unplanned downtime include reliable, ruggedized hardware for software applications, providing redundancy and cybersecurity. Chumbley said multi-site implementations are aided with templates to apply application software identically, reducing overall cost to implement, test and commission each new site.

Edge computing allows multiple types of automation software applications to be integrated on one hardware platform, prevents downtime by ensuring application reliability, enables scalable and repeatable implements, and provides a means for system integrators to continue to help customers with support services. ce

Edited by Mark T. Hoske, content

manager, Control Engineering, CFE Media and Technology, also the moderator for this webcast, mhoske@cfemedia.com.

A JAN. 25, 10 a.m. central time webcast, “Tips on achieving scalable, repeatable, and protected automation solutions” provides advice on how to implement edge-computing-based automation across multiple locations, with benefits for system integrators and their customers. Image courtesy: CFE Media and Technology

controleng.com

KEYWORDS: Edge computing for automation, system integration

LEARNING OBJECTIVES

Edge computing has advantages for automation

Large, multi-site, critical automation application uses edge computing Edge computing for automation brings advantages to system integrators, their customers.

CONSIDER THIS System integrators: Can edge computing more reliably deliver automation architectures for your mission-critical applications? ONLINE

www.controleng.com/ webcasts/past

For MQTT Smarter is Better -

Here’s why.

MQTT is gaining popularity for connecting plant (OT) data to corporate IT departments or the cloud. And although it fits well in some applications, it could be better, especially for large, complex projects. Put simply, making MQTT smarter can make it more suitable for OT/IT or Industrial IoT connectivity.

Bigger Challenges

MQTT was developed for low resource use and quick implementation. It does well connecting field devices to a central broker and providing access to the device data. But to connect entire plant systems to IT and the cloud, MQTT can struggle. Often a variety of devices in larger systems need to communicate with each other over MQTT using different data formats. Additionally, the simple, direct security model of device-to-client is insufficient when networks need to be isolated using DMZs.

Getting Smarter

To meet these challenges MQTT must get smarter. As a transport protocol, MQTT specifies that messages are simply carried—not read—like a letter in the post. But what if we gave an MQTT broker the ability to

interpret the messages it carries? It would be able to handle messages more intelligently, changing protocols and message formats to accommodate different client requirements, or even modify the messages to add useful information.

More Useful

With those capabilities, an MQTT broker could aggregate messages in different formats into a single, uniform stream. It could also queue incoming data intelligently, handling overload conditions in a way that guarantees consistency. It could act as a gateway to other standard protocols, convert among custom data representations and augment the data with connection quality information on each value update.

You can read more about these possibilities and others in a white paper: For MQTT Smarter is Better. Anyone implementing MQTT for OT/IT or IoT will understand the advantages of a smart MQTT broker.

info@skkynet.com skkynet.com

SCAN QR CODE AT RIGHT FOR SMARTPHONE ACCESS

How next-generation automation will help in 2023

As part of the 2023 “How to automate series” of webcasts, three firms selected as 2023 System Integrator of the Year explain how and what next-generation automation they expect will help their clients in the coming year. A summary of the Jan. 18 webcast, archived for 1 year, follows.

Control system integrators discussed how they anticipate next-generation technologies will help in 2023 in a Control Engineering Jan. 18 webcast that will be archived for a year. It’s the first

in a series of “How to automate” webcasts in 2023. Using research about technologies, interviews and other materials from automation industry leaders, this moderated discussion also will present Control

Engineering research about what technologies are expected to help most. Goal is to help users and those doing control system integration to identify automation technologies that will help advance competitiveness in 2023. A poll question will seek audience input about what technologies they find most useful. There is no cost to attend the 1-hour webcast, and 1 RCEP professional development hour is available with successful completion of a quiz after the webcast. Learn more and get the registration link in the online box: “Automation Series: How next-generation automation will help in 2023.”

March 8 is the next in the series. www.controleng.com/webcasts

Continued on page 47

In a Control Engineering webcast, Jan. 18, 2022, archived for a year, “Automation Series: How next-generation automation will help in 2023,” award winning control system integrators Eosys (graphic upper left), George T. Hall (upper right), and NorthWind Technical Services (lower left) explain what technologies are helping their clients automate more effectively in 2023. These are the three System Integrator of the Year firms for 2023. Courtesy: Eosys, George T. Hall, NorthWind Technical Services, Control Engineering

PLC module coordinates real-time data in coal shipping application

A coal shipping company improved their supply chain and operations by reducing inefficiency and waste.

Neptune Bulk Terminals handles a large portion of the Canadian steelmaking (metallurgical) coal exported to overseas markets annually, and it is an important contributor to the Canadian economy. Reducing environmental impact, costs and processing times are high priorities across the supply chain.

However, an inability to know or control realtime status and real-time routing can lead to inefficiencies, taking the form of missing customer commitments, lower capacities, higher costs and avoidable shutdowns. Streamlining delivery of this information often involves bridging the gap between operational technology (OT) and information technology (IT), enabling users to maximize efficiency and boost visibility across the shipping plant.

Until now, many manufacturing and shipping plants have relied on manual processes, or software and computers, to integrate programmable logic controllers (PLC) to business systems to manage operations. However, these tools come with challenges associated with hardware and software compatibility, security risks and system interdependence. Fortunately, there are industrial built-forpurpose tools that eliminate the PC and customer software code and let users seamlessly integrate IT and OT in a way that enables bi-directional data exchange between enterprise systems and PLCs, unlocking many benefits across the supply chain.

QCA Systems LTD recently won an award for successfully integrating its OT and IT systems in a coal shipping plant. With more than 30 years of experience, QCA is Canada’s most dominant electrical engineering and automation company in the bulk material handling industry. To improve end users’ productivity and reduce overall manufacturing costs, the company uses its experience integrating industrial and commercial systems, making

them secure and creating real-time and historical views of site process data. In one case, they used an industrial, built-for-purpose, in-chassis PLC module to improve efficiency.

Changing conveyor routes and cargo train conditions

In this application, steelmaking coal comes in from cargo trains, is processed on-site and loaded onto large Handymax or Cape-size vessels. Inside the terminal, shipments are processed through a network of conveyors that must accurately move the coal to and from the cargo transports. The conveyor system, which consists of multiple routes, is crucial to the successful distribution of shipments to the target destinations.

However, these routes are subject to change. Variables such as the volume of imported coal, different grades or load capacity of vessels, can influence the path of a shipment, causing it to deviate from the predetermined route. The shipping plant needed the most accurate real-time information

Keywords: programmable logic controller, I/O module

LEARNING OBJECTIVES

Learn how a shipping company improved their operations efficiency using a built-for-purpose operational technology (OT) to information technology (IT) connectivity solution.

Learn why not knowing real-time status and realtime routing can lead to inefficiencies and downtime. ONLINE

Learn more about tManager here.

CONSIDER THIS

How are you using realtime data to improve your operations?

FIGURE 2: In this PLC application, steelmaking coal comes in from cargo trains, is processed and loaded onto large Handymax or Cape-size vessels. Inside the terminal, conveyors move the coal to and from the cargo transports.

‘

The company needed a sitewide management system, integrated to the routing PLC at the OT control level. ’

available to successfully adjust its procedures to these evolving circumstances.

Although PLCs stationed along the conveyor routes control the movement of coal, in the event of a process interruption, there was no visibility into a faulty conveyor’s real-time status. There was also no visibility into other nearby conveyors with spare capacity, and no visibility into the higher-level business system, which managed the entire process and logistics.

At this site, PLCs communicated to one PLC that controlled the routes. In order to improve effi-

ciency, the company needed a lean site-wide management system at the IT business level, and this site-wide management system needed to be integrated to the routing PLC at the OT control level.

Improving operations with an in-chassis PLC module

To integrate the site-wide management system into the PLCs, QCA selected an industrial, builtfor-purpose, in-chassis PLC module that installs in ControlLogix PLCs. The device acts as the messenger between the PLC and enterprise system, such as Microsoft structured query language (SQL) databases, and eliminates the PC server, software and scripting oftentimes required to orchestrate transactions between the two. By connecting the lean management software system to the enterprise SQL database and connecting the PLCs to the SQL database, it was able to transport critical information bi-directionally to PLCs, enabling personnel in the coal shipping plant to modify their plans with the most accurate and up-to-date information available.

Previously, plant operators could only monitor the expected arrival time and availability of inbound trains and outbound ships, creating operational dead spots if the wrong train arrived for drop-off or the conveyor stopped processing for a single route, for example. The module addressed these issues by providing greater operational visibility.

FIGURE 3: Dumper Automatic Equipment Identification (AEI) graphic shows the data transacted to and from the PCS database to the PLC.

Routing data is moved from the PLC and stored in a database or other cloud application. In the event of a process malfunction, the module overwrites the old status information in the database to reflect the new route status. In turn, it gets new status information from the database and writes this to the PLC to reroute traffic. Not only does this strategy limit the risks associated with misplacing a product, it also provides detailed realtime information, following the product from the beginning to the end of the cycle.

Centralizing and connecting information with machine control reduces manual processes, increases overall plant efficiency, reduces risk, improves customer commitments and can even lead to valuable metrics for analyzing processes for overall process improvements.

The module also avoids potential pitfalls associated with using PCs and custom coding to integrate business systems with industrial PLCs because it requires no updates, provides better security and is tied to the controller. It also avoids relying on the complicated dance between servers, software and networks for planning and execution.

Improving operations management and supply chain

In this application, the module controls the company’s site-wide routing process, while a second and third module manage the importing train systems, as there are two railcar dumpers in this application — each with its own system. Thanks to these devices, the shipping plant now has a more holistic view of its entire shipping process, allowing it to adapt on the fly. Not only is it less complex, it requires no coding, programming or servers.

Thanks to QCA’s engineering and automation expertise in designing and implementing this intelligent routing system using a built-for-purpose OT to IT connectivity solution, the plant has improved its efficiency without having to expand its facility’s footprint that can be implemented in future projects. ce

Deane Horn is director of product management at Softing. Edited by Chris Vavra, web content manager, Control Engineering, CFE Media and Technology, cvavra@cfemedia.com.

FIGURE 4: The SQL sends an expected car list to the respective PLCs. When a coal railcar enters the dumper, it is read by the AEI readers and matched with the car details from the expected car list. Once dumped, the actual production data for that railcar is sent to the PCS database using the Softing tManager, an industrial, built-for-purpose, in-chassis PLC module that installs in Rockwell Automation ControlLogix PLCs.

FIGURE 5: Production plans received from the SQL to the PCS, showing the defined source-to-destination plans that the routing system ties to a running route.

Insightsu

PLC insights

uIntegrating programmable logic controllers (PLC) to business systems to manage operations used to be a manual process, but module technologies can help coordinate them and become more automated.

uQCA Systems LTD selected an industrial, built-for-purpose, in-chassis PLC module that acts as the messenger between the PLC and enterprise system using structured query language (SQL).

Analysis: Ability to delay Microsoft DCOM hardening patch ends as of March 2023

The mandatory Microsoft DCOM hardening patch, “one of the best changes Microsoft has made for DCOM,” effects only a small percentage, but still a large number of applications. There’s no postponing the patch as of March. Be aware of the impact and related misinformation.

OPC TRAINING INSTITUTE offers training and services on topics including OPC and DCOM diagnostics, OPC security, OPC Unified Architecture (OPC UA) and advanced OPC projects. https://www.opcti.com/OPC-course-abstracts.aspx has more information

While the Microsoft mandatory distributed component object model (DCOM) hardening patch effects a small percentage (still a large number) of applications, the ability to postpone the patch ends in March. See effects on OPC and four solutions if unable or unwilling to update.

OPC Foundation is providing warnings so vendors, integrators, and end-users are aware of the upcoming potential problem. Since approximately 90% of OPC applications connect to local clients and servers, they will be unaffected. The remaining 10% have potential for problems. OPC Training Institute estimates only about 1 in 40 applications are affected; only about 0.25% of all connections would be affected. While a small percentage, it represents a large number of installations, perhaps a few thousand (one application could have multiple installations). Most affected applications are customized installations or developed by small organizations with few sales.

The OPC Training Institute, separate from the OPC Foundation, provides in-depth training on OPC Classic and OPC UA with services for testing and verification for affected DCOM installations and programming consulting and/or services.

Microsoft DCOM patch impact on OPC

The DCOM hardening change affects some (not all) people who use OPC, those installations using:

• OPC Classic (which is based on DCOM). It does not affect OPC UA (which does not use DCOM).

• Connections over a network. It does not affect local connections.

• Newer Microsoft Windows versions. It does not affect Microsoft Windows 7 and Microsoft Windows XP.

• Applications forcing DCOM security to a low level. It does not affect applications using default settings.

Microsoft’s DCOM hardening forces all networked DCOM communication to have a high security

level. In my opinion, this is among the best Microsoft DCOM changes. It shows Microsoft still considers DCOM relevant, otherwise Microsoft would leave DCOM alone or remove it. The change shows Microsoft is serious about security.

Sadly, myths remain about DCOM going away. DCOM was released in 1996, and myths began as early as 1997. Yet Microsoft keeps supporting DCOM. DCOM is not going away; even Microsoft Windows 11 uses a lot of DCOM technology. DCOM provides a high level of security and works well with firewalls, workgroups, domains, and access control lists. Those who take a bit of time to understand DCOM security are able to tame DCOM, while others keep complaining about the complexities.

Four solutions if not updated

For organizations unable or unwilling to update their software, OPC Training Institute recommends four possible solutions, in order of best to worst:

1. Fix the problem's cause programmatically. Programmers need to find the cause of the problem (CoCreateInstanceEx) and change the hard-coded security setting. This will necessitate programmers to recompile their code. Programmers using a third-party OPC component (DLL, LIB, OCX, etc.) will be unable to make the fix.

2.Use a tunnel in either a half- or full tunnel configuration.

3. Temporarily disable the patch: This only will work until March 2023.

controleng.com

KEYWORDS: Microsoft DCOM patch March 2023, OPC

LEARNING OBJECTIVES

Microsoft DCOM patch impact on OPC, increased security level, 4 solutions for the DCOM update. OPC Training Institute offers courses and services.

CONSIDER THIS

Do you have a Microsoft patch plan? ONLINE

OPC Training Institute https:/www.opcti.com https://www.industrialcybersecuritypulse.com

4. Do nothing: Do not patch Microsoft Windows and work with an unpatched version of Windows.

Given a competent crew, most organizations will be able to patch as needed. Even if a repair is available, they may not be able to shut down systems to conduct

the repair, so attention is required. ce Randy Kondor, P.Eng., is chief technology officer, OPC Training Institute. Edited by Mark T. Hoske, content manager, Control Engineering , CFE Media, mhoske@cfemedia.com.

Inertial measurement unit sensors lower risk for autonomous vehicles

By using accelerometers and gyros, intertial measurement unit sensors integrated into autonomous vehicle, are designed to lower risk in an emergency stop if other sensors fail.

TInsightsu

Position sensors

uWhile many vehicles are already equipped with autonomous technologies such as assisted parking and automatic braking, fully autonomous driving requiring no driver interaction is still some time off.

he future of vehicles is autonomy, and advanced position sensor technologies are helping vehicles designed to drive themselves—safely and accurately. There are many predictions regarding when truly autonomous cars will become a reality.

However, while we wait, many of today’s vehicles are equipped with a variety of advanced driver assistance systems (ADAS) like lane departure warnings, assisted parking, and automatic braking. Although these technologies are very useful, they are considered an SAE autonomy level of just 1 or 2, which means that they still require driver engagement 100% of the time.

The big question is when will we see the technological leap to level 5, or fully autonomous vehicles that require no driver interaction. Unfortunately,

FIGURE 1: IMU sensors rely on gravity and physics of motion. Unlike vision, radar, LiDAR and other perception sensors, as well as steering systems based on GNSS signals from satellites, IMU based guidance systems are not affected by harsh environmental conditions and physical obstructions like tunnels and foliage and will continue to operate. All images courtesy: Aceinna—Inertial Measurement Systems

we are still several years away from this technology becoming widely accepted and adopted into any type of vehicle. Why? The critical challenge is ensuring safety.

To achieve full autonomy requires absolute confidence that a vehicle will continue to safely and accurately operate in any type of weather or road conditions and will avoid significant injury to passengers, pedestrians, or property.

This would require a built-in guidance and navigation technology that can ensure the vehicle will operate safely if and when vehicle perception sensors like LiDAR, radar, or cameras fail, or if there is an intermittent disruption in GNSS satellite signals due to weather, terrain, or environment.

Safe-stop sensing system for autonomous vehicles

This vehicle sensing technology is the inertial measurement unit sensor, or IMU sensor. Because an IMU sensor is based on gravity and the laws of physics rather than external conditions, it can continue to send data so the vehicle can safely maintain course until it can come to a secure stop or the other navigation systems start functioning again, even if the perception sensors fail because of weather. By eliminating data interruption and increasing operational safety, the IMU will expedite the reality of Level 5 fully autonomous driving.

The bottom line is this: Without IMU sensors to provide the safety cushion, autonomous vehicles will never be able to effectively work in city streets and highways.

What is an IMU sensor, and how does it work?

Most IMU sensors are composed of two different sets of sensors—accelerometer sensors and gyroscope sensors. The accelerometer sensors measure linear acceleration in three orthogonal axes. Integrating acceleration over time will provide velocity, and integrating velocity over time will change result in a change in position.

FIGURE 2: An IMU uses its accelerometer and gyroscope sensors to capture measurements over six degrees of freedom, three axes of movement (forward and backward, left and right, and up and down), as well as three axes of rotation (roll, pitch and yaw).

The gyroscope sensors measure the angular rate of three orthogonal axes. Integrating the angular rate along the three axes over time will generate change in roll, pitch, and yaw, which is the change in attitude of an object.

An IMU module with gyroscopic and accelerometer sensors can provide measurement over 6 degrees of freedom (often called 6-DOF, see below).

‘Triple redundant IMU sensors provide an extra level of safety, accuracy and reliability that is required to lower risk for operation of autonomous vehicles on highways.’

It is a direct measure of how much the gyroscope drifts over time. Because the rate output of the gyroscope is being integrated to calculate change in angles (roll, pitch, and yaw), any error associated with drift results in accumulated error in relative angles. Furthermore, these angular errors translate into position errors over time. For automotive applications a high performance IMU is

FIGURE

3 : Aceinna’s Triple Redundant IMU sensors provide the extra level of safety, accuracy and reliability that is required to ensure safe operation of autonomous vehicles on highways and in dense urban environments.

Why do some IMUs also include a magnetometer?

An accelerometer can be used to successfully calculate roll and pitch values with respect to earth’s gravitational force, and correct gyroscope drift.

However, it cannot be used to detect absolute heading (yaw) because the change of yaw is orthogonal to the gravity vector. A magnetometer measures the magnetic field strength in three dimensions. By using the Earth’s magnetic field, it can help to determine heading (i.e., yaw) as well as roll and pitch of the object.

Integrating a magnetometer in the IMU can help with detection of the initial heading of an object and correct integration errors of the yaw gyroscope in the sensor fusion algorithm.

IMU measurement;

IMU triple redundancy

Bias instability is one of the most critical performance parameters of the gyroscope.

a necessary component for the autonomous vehicle to achieve high accuracy positioning.

In a triple redundant IMU, three IMUs are used to construct a triple-redundant sensor architecture that provides additional levels of reliability and accuracy.

If for some reason one or more sensors is not accurately functioning, the system can be programmed to recognize the defective sensor data and avoid using it. The defective sensor output or errant dataset will be ignored or de-rated in importance. This architecture ensures the reliability of the system and simultaneously improves the performance.

IMU sensors may not attract the same amount of attention and media coverage as other sensors— i.e. LiDAR Radar, and cameras. However, in many ways IMUs are the critical safety sensor component required for the successful operation of the Level 4 and 5 autonomous vehicles that will be appearing on streets within the next decade. ce

James Fennelly is product manager, Aceinna—Inertial Measurement Systems. Edited by David Miller, content manager, Control Engineering, CFE Media and Technology, dmiller@cfemedia.com.

Keywords: Safety sensors, autonomous vehicles, IMU LEARNING OBJECTIVES

In automotive applications a high performance IMU is a necessary component for the autonomous vehicle to achieve high accuracy positioning.

In a triple-redundant IMU, three IMUs are used to construct a triple-redundant sensor design adding reliability and accuracy.

ONLINE

Precise position for autonomous vehicles

https://www.controleng.com/ articles/precise-positioningfor-autonomous-vehicles/ How MEMS sensors are changing automotive applications

https://www.controleng.com/ articles/how-mems-sensorsare-changing-for-automotiveapplications/

Embedded sensing in autonomous navigation

https://www.controleng.com/ articles/embedded-sensingin-autonomous-navigation/ CONSIDER THIS How will the development of Level 5 commercial vehicle autonomy affect mobile industrial technologies?

A3 Forum: Optimism, caution on automation, economy

uThe A3 Business Forum in Orlando, held by the Association for Advancing Automation (A3), brought manufacturing thought leaders and executives together to learn more about the state of the manufacturing industry. Additional sessions discussed some of the innovations being put forth by different companies and the impact they’ve having on their respective industries.

“When you think where we’re headed as an automated society, everyone needs to benefit,” said A3 president Jeff Burnstein in the event’s opening speech.

Beaulieu on manufacturing

The global economy has endured headwinds in the last few years; the COVID-19 pandemic changed the way we work and operate. The next several years also will have challenges and opportunities, said Alan Beaulieu, principal and president of ITR Economics, at his presentation “Calculate to Win.” A recession, he said, is very likely going to happen in 2024 due to rising interest rates imposed by the Federal Reserve to stave off inflation. It’s a measure, he said, that is unnecessary, but will likely be mild. Manufacturers will be better-positioned than other industries in general due to high demand for products. Automation will help. In general, businesses remain profitable and liquidity is high, Beaulieu said, and consumer financial health is good with incomes rising overall. The labor market will remain tight and the weakening economic conditions in the years ahead mean employees will be more likely to stay.

Who are the ones who are going to keep things running? The more you do that, the more you can help your country grow. That’s an advantage. You’re in the right industry.”

Automation, growth

‘ Automation can fill the gap by providing the productivity needed to continue achieving future economic growth.’

Automation is a $100 billion market compromised of robotics, software and artificial intelligence/machine learning (AI/ ML) and hybrid markets that take advantage of the Industrial Internet of Things (IIoT). Gaurav Mittal, managing director, technology and business solutions, Thomas H. Lee Partners, said automation touches nearly all end markets and industries today, and it will continue to grow, according to his presentation “The Growth Opportunities for Robotics from the Venture Capital Perspective.”

Automation opportunities

In a roundtable discussion, “New opportunities for automation,” four industry leaders explained how automation has helped.

Users need to sift a lot of data for actionable results. Stephanie Cannon, senior VP of operations excellence and collaborative innovation at Pitney Bowes, said this is a challenge in warehouse automation. “We need scalability and data,” she said. “Clients expect accuracy, quality and speed.”

“The world is going to need you for decades. You’re the heroes,” Beaulieu said. “Who is the most-needed people? You.

Automation, Mittal said, will be a key force driving global gross domestic product (GDP) growth. Historically, employment growth and productivity were about even in terms of GDP. That is going to change because the workforce is getting older overall, and there is less need for people on the plant floor. Automation can fill the gap by providing the productivity needed to continue achieving future economic growth.

Darcy Bachert, CEO at Prolucid Technologies Inc., helps improve automation in industries such as nuclear engineering and medical. “We have an aging population. We need to find ways to bring costs down through technology, and there’s so much opportunity to solve these big problems.”

Mark DeSantis, CEO at Bloomfield Robotics, talked about use of robots, advanced sensors and vision technologies to automate crop picking.

For Brad Bogolea, CEO and co-founder of Simbe Robotics, his challenges are to bring an autonomous robot into a busy retail environment to examine empty shelves, and convince workers the robots were there to augment their jobs rather than replace them. Read more from Beaulieu, Mittal and the panel (see photo) with this article online. ce

Chris Vavra, web content manager, Control Engineering, CFE Media and Technology, cvavra@cfemedia.com.

LEFT TO RIGHT: Brad Bogolea, CEO and co-founder of Simbe Robotics; Stephanie Cannon, senior VP of operations excellence and collaborative innovation at Pitney Bowes; Mark DeSantis, CEO at Bloomfield Robotics; Darcy Bachert, CEO at Prolucid Technologies at the A3 Business Forum in Orlando. Courtesy:

Chris Vavra, CFE Media and Technology

LOW-VOLTAGE ac motor market grows 21.2% in 2022

THE LOW-VOLTAGE (LV) ac motor market has fared well in terms of growth over the past few years, largely as a result of higher prices according to Interact Analysis research. In 2022, the market grew to $17 billion with prices increasing by around 35% to 40% in the first half of the year.

As prices rose exponentially in 2022, this allowed for a 21.2% growth rate for the LV ac motor market this year. However, it is expected that a slight price decline in the second half of the year will have a knock-on effect on revenue and growth rates. Looking out to 2023, price declines will continue, but the volume sold looks set to remain high, matching the 2022 rate. Overall, growth is expected to slow but not fall, as the current economic climate and high interest rates are likely to influence demand for LV ac motors, particularly within the machinery sector.

The demand for motors tends to mirror the performance of the manufacturing sector. In 2023, LV motors market growth is projected to slow to around 0.29% in unit sale terms, with revenues falling by >10% due to reciprocal price decreases. The manufacturing sector is also likely to experience slow growth in 2023 because of high interest rates and economic uncertainty caused by the Ukraine-Russia war. Many customers are thought to have overstocked in previous years and the motor market is emerging from this period of exponential demand. Taking a longer term look

at the market, it is anticipated that 2026 will see a year of economic decline affect sales.

Adoption of IE4 motors has been well received by EMEA and legislation regulating the efficiency of motors in the EU continues to be a driving force for the market. While EMEA has tended to produce the highest priced motors, IE4 legislation has pushed prices up further and has also forced other regions to increase the prices of their LV ac motors. By 2027, almost 30% of market revenues in EMEA regions will come from IE4 motors, in part because all 75kW and 200kW motors must be IE4 compliant in 2023.

Blake Griffin, senior analyst at Interact Analysis said, “Perhaps the most prominent finding we have from this report is the impact that price volatility is having on market growth. In our previous report, we expected prices to rise to a certain level and stagnate for a few years before declining. We have seen the opposite. The motor market is currently experiencing extreme price volatility and changes in the global economy, making forecasting very difficult. We can, however, confidently predict that prices will decline from 2023 onwards before they begin to stabilize in 2026/2027.” ce

- Interact Analysis is a CFE Media and Technology content partner. Edited by Chris Vavra, web content manager, Control Engineering, CFE Media and Technology, cvavra@cfemedia.com.

Automation mergers, acquisitions analysis: January 2023

uBundy Group, an investment bank and advisory firm, provides an update on mergers & acquisitions and capital placement activity in the automation market. Ten transactions were reported in a January summary (read this article online to see).

Three 2023 insights

With 2023 in full swing, the automation solutions segment is well positioned for another robust year in M&A and capital placement activity. While existing macroeconomic headwinds present some challenges, the Bundy Group team continues to be very optimistic about the growth of the automation market and the M&A and capital activity tied to the segment. Three interesting points to note:

1. Bundy Group was proud to have advised Avanceon, a full-service industrial automation and information systems integrator, in a sale to an international conglomerate. This is one of the first announced automation transactions of 2023. Vinci will expand its U.S.-based industrial portfolio with the acquisition,

and Avanceon and will join under the Actemium network, the Vinci Energies brand dedicated to the industry market.

2. An “In Demand” Subsegment: Bundy Group anticipates several closed deal announcements in 2023 in automated material handling services sector. Solutions include system integration, robotics, conveyors, fulfillment centers and electric vehicle production. The demand from strategic and financial sponsor buyers for these companies is incredibly strong, and we anticipate no shortage of offers in competitive processes for these organizations that we are representing in business sales.

3. The 2023 A3 Business Forum – An Atmosphere of Energy: I recently attended the Association for Advance Automation (A3) Business Forum and had great meetings with key players in the automation sector, and I heard positive industry comments from every person I met. Automation subsegments of particular interest include robotics, machine vision and automated material handling. ce

Clint Bundy is managing director at Bundy Group, a CFE Media and Technology content partner.

uOnline

AI risk management framework released NIST released its artificial intelligence (AI) risk management framework as part of a larger effort to build and instill trust in AI with the greater public.

Top 5 Control Engineering content: January 16-22, 2023

Most-viewed articles on Control Engineering included stories on industrial robot trends, hot Control Engineering topics, MQTT, motion control trends and Microsoft DCOM.

Researchers demonstrate strain sensors for machine interface technology

Researchers have developed a stretchable strain sensor that combines sensitivity and range.

Industrial software company acquisition completed Aveva announced the completion of its acquisition by Schneider Electric.

Geared products market to grow by 7.2% in 2022

With steep drops in commodity and freight costs anticipated in 2023, falling prices will see 2022's rapid growth rate slow.

in ControlEngineering for 2022 Hot topics

See product awards, motors and drives, automation salary and career information, Engineering Leaders Under 40, IIoT implementation help, HMI and SCADA tutorials, PLC programming help, top 3 covers and top 10 articles posted prior to 2022.

Mark T. Hoske Control Engineering

u

Online controleng.com

HKEYWORDS: Control Engineering, hot topics in 2022

LEARNING OBJECTIVES

Understand how Control Engineering hot topics for 2022 were selected.

Review top 10 articles posted during and before 2022 at www.controleng.com. See top 3 covers as selected by the Control Engineering creative director.

CONSIDER THIS

What did your Control Engineering peers read that also could benefit what you’re doing?

ONLINE

ot topics during 2022 in Control Engineering include award-winning automation, control and instrumentation products; a variable frequency drive (VFD) tutorial; advanced motor control tutorial; information about engineering salaries and career advice; and “Engineering Leaders Under 40,” based on Google Analytics for www.controleng. com, as tallied by Chris Vavra, web content manager. Other topics, rounding out the top 10 cover use of VFDs with permanent magnet motors; Industrial Internet of Things (IIoT) implementation help; tutorials on human-machine interfaces (HMIs) and supervisory control and data acquisition (SCADA); and programming help for programmable logic controllers (PLCs). Also see top 3 covers below with and top 10 Control Engineering articles posted prior to 2022. These automation and control topics help Control Engineering subscribers do their jobs better. For future automation coverage based on subscriber research and to contribute, see www.controleng.com/2023articles.

Hot topics, July-December, covers

Hot topics in the second half of 2022, under-represented in the tally above, include digital transformation using the cloud in July, leveraging IIoT for process optimization, modernization in August, how to find the best controller in September, control system alarm management in October, how AI and machine learning can drive sustainable 5G in November and leveraging MQTT industrial edge devices in automation projects in December.

This article online has links to each month, along with Top 10 articles posted prior to 2022.

Top 3 covers of 2022

Michael Smith, Control Engineering creative director, explained why January/February edge and AI-enabled IIoT, May resolving workforce challenges and August industrial wireless were his three favorite covers in 2022. Review these and other print/digital editions here:

https://www.controleng.com/magazine/

Smith said the January/February issue does a splendid job of communicating automation controls with the various tools and equipment today's modern engineers have at their fingertips. The artwork shows off some of the technology used for automation in a well-orchestrated cover design. Showing real people in engineering is always the best approach providing a tangible entry point for the reader.

The May issue is a perfect snapshot of young engineers from a diverse cultural backgrounds. The color design works to control the readability, while integrating into the format. Young engineers are in high demand due to a lack of skilled workers entering into the job market today. The photo serves as a visual hook and is an excellent example of education in the field.

The August issue is another great example of people and engineering. The primary subject, followed by cascading coworkers in the background for a pleasing and engaging format. Colorized type, size, and design are used to help communicate an integrated wireless message. ce

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Amanda Pelliccione, Director of Research 978-302-3463, APelliccione@CFEMedia.com

Gary Cohen, Senior Editor GCohen@CFEMedia.com

Chris Vavra, Web Content Manager CVavra@CFEMedia.com

Contributing Content Specialists

Suzanne Gill, Control Engineering Europe suzanne.gill@imlgroup.co.uk

Ekaterina Kosareva, Control Engineering Russia ekaterina.kosareva@fsmedia.ru

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

Mark Voigtmann, partner, automation practice lead Faegre Baker Daniels, www.FaegreBD.com

CFE Media and Technology

Contributor Guidelines Overview

Content For Engineers. That’s what CFE Media stands for, and what CFE Media is all about – 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.

www.controleng.com/contribute explains how to submit press releases, products, images, feature articles, case studies, white papers, and other media.

* Content should focus on helping engineers solve problems. Articles that are commercial or are critical of other products or organizations will be rejected. (Technology discussions and comparative tables may be accepted if non-promotional and if contributor corroborates information with sources cited.)

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* Deadlines for feature articles for the print magazines are at least two months in advance of the publication date. It is best to discuss all feature articles with the appropriate content manager prior to submission.

Learn more at: www.controleng.com/contribute

Darrell Halterman, Emerson

Making machine control open, secure

Adopting modern and flexible automation platforms helps OEMs and end users meet traditional production challenges while addressing newer concerns, such as supply chain issues, labor shortages and cybersecurity.

Traditional challenges facing original equipment manufacturer (OEM) machine builders, and the end users they serve, often involve maximizing production rates, quality and uptime. While these fundamental focuses remain relevant, there are other significant external issues increasingly impacting OEMs and their customers. Supply chain scarcity, skilled labor shortages and cybersecurity worries affect how OEMs are supplying their equipment, and what end users require (Figure 1).

In years past, the technology and functionality needed to tackle all these issues might only be available in flagship controllers, but today automa-

tion options have expanded. Modern automation options include high-performance compact controllers suitable for use with all types of machines, helping OEMs and end users handle problems effectively.

Modern and flexible automation platforms are making it possible to continue satisfying typical machine control needs, while providing new options for addressing the latest challenges in the current business environment, through application of recent innovations such as evolving Industrial Internet of Things (IIoT) capabilities. Adopting these advancing technologies helps OEMs and end users meet these and other challenges while improving their partnerships.

Fixing the supply chain

Supply chain issues introduce challenges for design and machine operation. At design time, developers may find it difficult to source various components and intelligent devices. Once in production, component changes may be needed quickly as material sources vary and manufacturing demands are altered, otherwise production output can come to an ungraceful halt.

Designers are best positioned to integrate flexibility into their machine controls when they select an automation platform built upon open hardware, software and communications standards (Figure 2). This creates more open systems and allows component substitution if supply chain issues limit availability.

Examples include:

• Devices equipped with gigabit Ethernet and integrated Ethernet switching.

FIGURE 1, COVER: OEM equipment is becoming far more sophisticated, and with the right open and secure automation technologies, it can address traditional and more recent performance concerns. Images courtesy: Emerson

• Development environments offering IEC 61131 and more modern programming languages.

• Native, pre-licensed, support for open-standards-based industrial protocols such as secure OPC UA, Profinet, Modbus TCP, IOLink and DNP3.

An open platform with a scalable runtime configured using common toolsets provides designers with the flexibility to select whatever devices are most available to meet the need. After a machine is up and running, these features help designers make realtime changes to optimize operations, reduce risk and improve competitiveness.

Matching labor skillsets to controllers

While traditional IEC 61131 industrial programming languages remain relevant, there is a shift underway as the next generation of workers enters the engineering and maintenance workforce. New personnel are more likely to be comfortable with modern programming languages, such as C/C++ and Python. Advanced applications, such as data aggregation and analytics utilizing machine learning (ML) or artificial intelligence (AI), are best implemented with these languages.

Other contemporary programming methods include taking advantage of portable code libraries, which fosters reusable, extensible and maintainable coding practices. Tag-based programming, userdefined data types (UDT) and user-defined function blocks (UDFB), implemented with common automation toolsets and broad built-in function libraries, make for easy code standardization, rapid deployment, and reduced risk.

Automation to withstand cyberattacks

As automation platforms become smarter and more connected with higher-level systems and the internet, cybersecurity concerns become paramount. To reduce the risk of cyberattacks and provide suitable protection, security must be natively built into every layer including:

• Product supply chains (using tools for verifying products have not been tampered with, and traceability of components used in products)

FIGURE 2: Machine automation architectures can be tightly coordinated when built on platforms supporting gigabit Ethernet with integrated switching, along with native support for open standards and protocols, and modern programming features.

• Hardware boot systems

• Core operating system services

• Software applications

• Communications and networking.

One of the key features of modern automation platforms revolves around open connectivity. Open connectivity only can be most effective when it is complemented by complete security-by-design.

Match the pace of automation

Traditional programmable logic controller (PLC) and programmable automation controller (PAC) controls are mature and remain essential, but new technologies continue to arise and change fundamental approaches to solving automation problems. Not all new technologies stand the test of time, though. OEMs and end users can struggle with how to best take advantage of what is available, without the perpetual worry of obsolescence.

The most reliable way to keep pace with this evolution is to work with a supplier offering a full portfolio of automation products, which includes PLCs and

controleng.com

KEYWORDS: machine control, original equipment manufacturer

LEARNING OBJECTIVES

Learn more machine control systems are evolving and being integrated with modern programming languages and increased automation.

Understand some of the challenges manufacturers and end users face with these control systems, which are vulnerable to cybersecurity attacks.

ONLINE

See additional discrete manufacturing stories at https://www.controleng.com/ discrete-manufacturing/

CONSIDER THIS

What are you doing to improve machine control at your facility?

ANSWERS

edge controllers are part of a wide-ranging portfolio of hardware and software, making it possible for OEMs and end users to create automation solutions scalable to any size.

Insightsu

Machine control

uSupply chain challenges, mixed with skilled labor shortages and cybersecurity issues are challenges manufacturers face today, but modern machine and automation platforms are helping improve plant floor operations.

u An open machine control platform using common toolsets provides designers with the flexibility to select whatever devices are most available.

PACs, and extending to edge gateways, edge controllers and edge industrial PCs (Figure 3). How does a full portfolio allow OEMs to keep pace? Using coordinated control and computing software based on open communications to support the data standardization, analytics, protocol conversion, and connectivity initiatives required by OEMs and end users.

Using these components let designers deploy new machines and build bridges between traditional islands of automation. Adaptable connectivity applies in two significant ways. First, support for OPC UA and other Ethernet industrial protocols makes it easy for machines to communicate with each other and with supervisory systems. Second, for processing plants with larger plantwide distributed control systems (DCS), support for NAMUR open standard module type package (MTP) means that machines – whether automated by PLCs, PACs, or edge controllers – are integrated with the DCS. This is a common requirement for companies using machinery in hybrid and process industries.

OEM and end user cooperation

Open and secure automation helps OEM and end users individually, and in partnership with each other. It elevates OEMs from selling machines to delivering a valuable range of services. It also accelerates end user efforts to optimize and coordinate all their operations, while expanding their support options.

OEMs adopting modern machine control platforms can deliver advanced IIoT solutions to their customers, giving both parties the ability to moni-

tor and support the equipment using real-time data and to apply analytics-based optimization. OEMs also gain the ability to provide tool-less fleetwide application deployment, updates, and standardized equipment tuning as well as secure remote firmware updates. Native communications authentication and encryption ensure these activities remain secure. Integrated intellectual property locks help OEMs deploy their most advanced developments.

End users benefit from gaining easy access to their valuable operational data, and the peace of mind derived from knowing their OEMs can keep their machines running at optimal efficiency via secure IIoT connectivity. Many users find their machines do not provide full functionality or value if they are installed as standalone islands, but it is often difficult to properly integrate many different makes and models. Modern machine control platforms, using open-standardsbased communications and capabilities like MTP, empower end users to integrate many different machines and subsystems for more comprehensive operational views and insights.

Integrating more capable controllers

For machine control, it is no longer enough to focus on the traditional challenges of production, quality, and uptime on a per-machine basis. OEMs and their end user customers are faced with additional external pressures related to supply chain disruptions, recruiting and retaining qualified personnel, and defending against cyberattacks. By adopting modern automation platforms and technologies, which include high-performance compact controllers incorporating a wide range of native open connectivity support, contemporary programming capability and built-in security. This helps OEMs and end users can overcome these and other challenges. They also are empowered to prepare for tomorrow’s challenges by creating new working models for efficient plant-wide integration, implementation of ML and AI technologies and improved remote support. ce

Darrell Halterman is director of PACSystems controls products at Emerson’s machine automation solutions business. Edited by Chris Vavra, web content manager, Control Engineering, CFE Media and Technology, cvavra@cfemedia.com.

FIGURE 3: The Emerson CPL410

COVER: HOW TO AUTOMATE WITH CONTROLLERS

Aaron Crews, Emerson

Taking control of your control system

Today’s input/output (I/O)-agnostic control solutions help plants break free of provider “lock in,” providing more choice and faster return on investment in modernization projects.

Today’s process manufacturing plants are under a lot of pressure. These plants are often using control technologies that are 20 to 40 years old. In many cases, the control system is reaching end of support, which can lead to many problems.

Supply chain issues make it harder to find replacement parts for aging control systems, generating long lead times and extended outages. Support, when available at all, is often limited, and a shortage of personnel experienced with legacy systems means long wait times for help. Many of the best practice safety and efficiency features automation technologies are either difficult to connect or not available with legacy control systems.

All these problems are compounded by the corporate office calling for better performance, higher efficiency and more sustainable operations, which are difficult to achieve without the right automation technologies. As a result, many plants are looking to modernize control systems, and many are finding new technologies provide greater choice without breaking budgets or creating extended operations outages (Figure 1).

Reasons to modernize the control system

The modern plant is very different from common facilities of just 10 short years ago. Today’s plants no longer have a deep bench of experienced personnel who can intuitively diagnose and manage operations and maintenance issues. It will be a long time before today’s new plant personnel have that level of experience and intuition.

As a result, successful plants rely on decisionsupport technologies built into automation. Mod-

ern control systems are designed to intuitively integrate the automation solutions that make plants safer and more reliable. Today, pervasive sensing components monitor each asset in the plant to ensure it will at peak performance. These components send collected data to operators in the control room, along with actionable advice to keep processes running at their best. Alarm management software eliminates alarm floods, keeping plant personnel safer, while helping them avoid environmental incidents. Advanced process control (APC) helps lock best practices into the system, so units and plants run at their best, regardless of the experience level of operators (Figure 2).

FIGURE 1: Modern automation technologies, like Emerson's DeltaV distributed control system Version 15, bring a wide array of advantages over legacy systems, providing fast return on investment. Images courtesy: Emerson

ANSWERS

All these technologies and more help plants run at peak efficiency, which helps create a competitive advantage. But they also are all difficult – and sometimes impossible – to implement with legacy control technologies. For this reason, many plants are looking to modernize control systems to take advantage of the easy integration provided by modern automation, but to do so, they must often look past traditional modernization methods to more affordable and efficient solutions.

Insightsu

Control systems

uProcess manufacturing facilities are often running legacy equipment that is decades old and cannot meet current company demands. They’re also more prone to breakdowns and failures, which adds to downtime costs.

uModernizing a control system is a daunting task, but agnostic input/ output (I/O) systems can help ease some of the burden for manufacturers by giving them a solution that doesn’t require a total shutdown or cost an exorbitant amount of money.

A better way to modernize controls

Operations teams know control system modernization is the answer to many of the problems they face in the plant, but many teams face a conundrum; the control system with the features they want and need is from a different automation supplier than the legacy control system they have in place. Changing control systems often means rewiring and replacing the I/O, which is a time-consuming, expensive and error-prone process that also extends outages. Project teams often struggle to build a business case for the modernization they need in the face of tight capital expenditure (CAPEX) budgets and limited tolerance for extended production outages. Because it requires the re-termination of thousands of wires and replacement of dozens of system cabinets, the replacement of existing I/O can be expensive, time consuming and risky. Every person

committed to manually transitioning I/O to a new control system is someone not focused on other valuable tasks in the plant. The fewer people committed to the task, the longer a cutover will take, leading to an increase in lost production.

In the past, the only solution to this problem was incremental upgrades from the same control system manufacturer, which is still time consuming, but less so. But such a strategy is unlikely to deliver all the best practice technologies a team needs, and leaves plants “locked in” to a single vendor every time they want to upgrade, regardless of whether or not that vendor offers the required technology and support.

Today’s I/O technologies offer companies choice and flexibility in control system selection regardless of the legacy technology. Today’s project teams can choose an I/O-agnostic interface to connect a new control system directly to legacy I/O without the need to rip and replace old wiring and terminations. An I/O-agnostic interface can reduce the downtime and complexity of modernization while also reducing CAPEX costs.

Modern controls, less downtime

Traditional modernization projects often require large project teams with many personnel on the ground to transition old I/O to new I/O before a new control system can be brought online. Often, the number of terminations that must be converted numbers in the tens of thousands, which can take weeks or months of manual labor, depending on the size and skill of the transfer team.

Using I/O-agnostic interfaces, project teams eliminate the need to transition legacy I/O before starting up the new control system. Instead, an I/Oagnostic interface operates as a bridge between the old components and the new control system. The team only replaces the existing controller and operator interface components, connecting the new controller via a communications cable that connects to the I/O-agnostic interface. Using this strategy, the project team can choose the scale of its modernization: controller-by-controller, consoleby-console, or by facility area (Figure 3).

Traditional modernization of a plant with 20,000 I/O controlled by 50 controller nodes might take months or years. The process would require dozens of technicians tracing, replacing and re-terminating wiring over many hours. Leveraging an I/O-agnostic solution can dramatically cut modernization time.

FIGURE 2: Modern control systems make it easy to take advantage of automation technologies that are now considered manufacturing best practices.

The project team can instead replace controllers individually, leaving the legacy I/O in place to gain all the benefits of modern control without the cost and hassle of a full rip-and-replace overhaul.

Shift costs to ease budget strain

No project team has unlimited budgets, but as plants face increasing pressures to improve throughput, efficiency and sustainability, today’s project resources are often even more limited than they used to be. Teams have other critical projects drawing from the same funds, and every dollar spent on modernization is a dollar unavailable for other initiatives.

Many project teams are finding I/O-agnostic solutions provide them the fiscal flexibility they need to complete modernizations without derailing other critical initiatives. Instead of one massive capital expenditures (CapEx) spend on ripping and replacing old I/O, the team instead leaves I/O in place, removing that cost from the project budget.

Because the I/O-agnostic interface empowers the team to cut over I/O on its own schedule, they can choose to transition legacy I/O after the cutover, while the plant is operational. This strategy moves I/O change to the operations budget, and it can be part of the budget for as long as it takes to complete cutover.

The act of modernizing the control system is often a money-saving choice in itself. The cost of supporting legacy systems is often high. Few companies maintain a deep bench of personnel with experience in decades-old control technologies, and even when those experts are available, they’re often expensive and only arrive after long waits, which is an expensive proposition if a unit or plant is down because they’re waiting for a technician to arrive.

Moving to a modern control system gives the plant access to a much wider range of available support personnel. Whether the plant is hiring new technicians who will have been trained on the newest control technologies or relying on consultant support from a trusted automation provider, support of modern systems is often more available, efficient and cost effective.

Consider an enterprise with hundreds of thousands of I/O points across the fleet. Modernizing the whole system would be an overwhelming undertaking and unlikely to get started even if necessary. In such a situation, implementing an I/Oagnostic solution lets the organization move all

FIGURE 3: I/O agnostic solutions, like Emerson's DeltaV IO.Connect, provide a path for process manufacturers to adopt the newest control technologies from their supplier of choice, without replacing existing I/O.

its plants to new, efficient and effective control technology while leaving the costliest element to replace – the I/O – in place.

The organization not only gains the financial benefit of transitioning I/O gradually over the next 5 to 10 years as part of the operations budget, but they also gain the advantages of the new control technologies for better performance, and higher throughput, making it easier to meet higher benchmarks and generate fast return on investment.

Eliminate control system roadblocks

In a world of tight budgets, short staffing, and increasing needs for continuous manufacturing, modernization projects can seem out of reach. Sometimes, it can seem as though keeping legacy systems running or slightly updated – is the only solution.

The truth is I/O-agnostic interfaces are changing the paradigm of control system modernization. Today’s plants can reap the benefits of best-practice technologies like alarm management, advanced process control, predictive maintenance and more while leaving existing I/O in place. This helps eliminate a large percentage of the costs, time and risks associated with modernization. ce

Aaron Crews is global director of modernization at Emerson. Edited by Chris Vavra, web content manager, Control Engineering, CFE Media and Technology, cvavra@cfemedia.com.

KEYWORDS: control system, I/O systems

LEARNING OBJECTIVES Understand the costs and challenges process manufacturing plants face due to running legacy control systems.

Learn about the benefits of modernizing a control system beyond improved operational efficiency.

Learn how input/output (I/O)-agnostic systems can provide a cost-effective solution without requiring a full rip-and-replace.

ONLINE

Learn more about control systems at https://www. controleng.com/articles/ the-control-system-is-key-tooptimal-loop-tuning/ https://www.controleng. com/articles/the-controlsystem-is-key-to-optimalloop-tuning/

CONSIDER THIS

What steps are you taking to modernize your plant?

ANSWERS

Jon Breen, Breen Machine Automation Services LLC

PLC programming: Do this, not that

Programmable logic controller (PLC) programming is often done to resolve an immediate problem, but this can lead to long-term issues, particularly if the original programmer isn't around. See PLC programming tips to follow and avoid.

u

Online

controleng.com

KEYWORDS: PLC programming

LEARNING OBJECTIVES

Programmable logic controller (PLC) programmers have a tendency to write code for immediate solutions rather than the long-term, which can be a problem for those picking up the work later.

Some PLC programming things to avoid include copy/ pasting repetitive logic and using indecipherable tag names with no labeling.

Some PLC programming best practices: Look for opportunities to reuse useful code; use descriptive tag names for easier searching.

ONLINE

https://www.controleng. com/articles/plcprogramming-dos-anddonts-to-consider/ CONSIDER THIS

Are you enabling or disabling future PLC programmers touching your code?

Production is down and the client is losing $100,000 an hour, and they’ve called a programmable logic controller (PLC) programmer to fix it as quickly as possible. The programmer fires up a virtual private network (VPN) while looking at last minute flights. An hour later, the programmer is staring at a new (to them) program, thousands of rungs of ladder logic, no tag descriptions, unclear naming conventions, code that’s been copy and pasted a hundred times, and it’s all in one, massive routine. This might lead to the programmer wondering what the original programmer was thinking.

PLC programming: Eight tips to follow; five practices to avoid

The average PLC programmer has a tendency to write code for themselves for the immediate solution. It’s easy to forget about the poor sap that has to maintain this in the future. If we’re not mindful, we may very well become the reason someone is shouting expletives at their screen. Here are some simple tips on how to not be that programmer.

DON’T – Copy and paste repetitive logic. Let’s say there are two coils you want to activate in sequence. A rung to turn on the first one, maybe a delay timer, and then a rung to turn the next one on. Aside from changing the tag name from

“CoilOne” to “CoilTwo” the rungs are identical. We all have code like this because usually that’s all it is, just a couple rungs. But what happens when you’ve got 50 coils? Before you go hammering on Ctrl+V…

DO – Look for opportunities to reuse code. Loops are your friend. AOIs, subroutines, and even basic arrays can speed up development time, keep code cleaner, and make future maintenance easier. Logic change? You don’t have to paste 50 fixes, just one small change to your subroutine and you’re done. What? The client wants 50 coils to now be 100? If you did it right you should literally just have to change a tag, “Coil_Count” or whatever, from 50 to 100.

DON’T – Use indecipherable tag names with no labeling. “tmrdelay” – “Timer” and “delay” are redundant. What’s this delay for? Are we using this to flash a light or wait a safe amount of time before lowering a heavy press?

“AB_XGI:I.Data[1]”, Obviously, this is a data structure for some connected device but referencing it like this in your main routine is throwing away an opportunity for self-explanatory code.

“fireRobotMove”, Which robot? Which move? Do I need a fire extinguisher? These tag names aren’t useless, per se, but without context they don’t mean much.

DO – Use descriptive tag names. The name should say what the tag is for. Care should also be taken with formatting. Even “tmrDelay” or “tmr_ delay” would be better. Nobody should have to guess at the word separation.

DO – Add descriptions to tags and rungs. A simple buffer routine or alias can turn “AB_XGI:I. Data[1]” into something more useful like “partXPos”. “tmrdelay” could become “tmrDrivesReady.” Even better would be a description on the tag or rung that explains what it’s for.

DO – Use proper spelling. Ever tried to find all the tags dealing with position data and one of them is spelled “poistion”? Yeah…

‘ Write code that is maintainable and flexible by using data structures, organization, consistent naming styles, and descriptive comments.’

DON’T – Neglect program structure. Nobody wants to sift through 200 rungs of a routine called “Main” that covers everything from input/output (I/O) to process flow.

DO – Use routines and user-defined data types (UDTs) (or “structs” depending on manufacturer) to stay organized. Simply breaking code up into a few routines called “Camera”, “InputBuffer”, and “Faults” automatically makes things more readable. No sifting through 50 rungs of unrelated logic – if you need camera logic search the “Camera” routine.

DO – UDTs are incredibly useful. They let you group and name data, even in arrays. For example, if you have a lot of position data coming back from your vision system you could keep it organized by creating a “Position” UDT with “X”, “Y”, and “Z” tags. “point1” with sub tags is far better than “point1X”, “point1Y”, and “point1Z”. Easier to rename, easier to cross reference, easier to stuff in an array and iterate through.

DON’T – Be optimistic:

“This project will only take a few months”

“Client knows exactly what they want”

“Nobody will ever see this but me”

or my personal favorite:

“I’ll remember why I did that.”

DO – Remember Murphy’s Law: “Anything that can go wrong will go wrong.” This point is really to highlight the necessity of all the others. A positive attitude is rarely a bad thing but if nothing ever went wrong, we probably wouldn’t have jobs. Things break, plans change, accidents happen.

THE AVERAGE programmable logic controller (PLC) programmer has a tendency to write code for themselves for the immediate solution, which can cause long-term headaches. Courtesy: Breen Machine Automation Services

Scalable, readable, maintainable code is Murphy’s mortal weakness.

The best thing we can do to prepare for an unknown future is be mindful of the above DO PLC programming statements. By using data structures, organization, consistent naming styles, and descriptive comments, we write code that is maintainable and flexible. This makes it easier for every person who has to look at the project in the future.

Your client will thank you when they need to add a new push button. Your coworkers will thank you for having an easy-to-follow structure. But in my experience the person you help most is yourself. Because honestly, 50% of the time that I’m complaining about code, it’s my own.

DON’T – Just make it work.

DO – Take the time to do it right. Work smart now to make work easier later. ce

Jon Breen is owner, Breen Machine Automation Services LLC; Breen Machine Automation Services is a CFE Media and Technology content partner. Edited by Chris Vavra, web content manager, Control Engineering, CFE Media and Technology, cvavra@cfemedia.com.

Insights

Don't let your learning end here. Also see: uHow to hire engineers other companies don’t know about uPLC programming: What you need to know u 7 tips every PLC programmer should know

ANSWERS

Thomas Burke, CC-Link Partner Association (CLPA)

Ethernet reliability in the age of IIoT, digital transformation

Ethernet can enable better IT/OT coordination and improve communications, reliability.

TOnline controleng.com

KEYWORDS: Industrial Ethernet

LEARNING OBJECTIVES

Ethernet has become the default for industrial manufacturing systems. Users can engineer Ethernet reliability into an application by knowing what products will be in use and coordinating use.

Ethernet with TSN can manage reliability with added bandwidth, communications scheduling and traffic management.

ONLINE

https://www.controleng. com/articles/ethernetreliability-in-the-age-of-iiotdigital-transformation/

See more on " TSN: Improved industrial network integration"

CONSIDER THIS

How have Ethernet networks helped your facility?

he continuous need to improve manufacturing processes and become more competitive is driving industrial communications advancements. Ethernet is advancing with new speeds and has become the default for industrial systems. While the slower moving automation market is still operating at 10 or 100Mb speeds, the information technology (IT) world is benefiting from 1 to 10Gb speeds. Some industrial networks are already delivering 1Gb support. While increased bandwidth helps to handle more traffic, it does little to improve reliability in a market that requires 100% reliability.

Users can engineer Ethernet reliability into an application by knowing what products will be used in the network and then coordinate use of the network. By default, this requires closed networks, which limits access to data. This limits the opportunities for continuous improvement and digital transformation. The manufacturing industry is constantly looking to improve performance, save costs and eliminate downtime. Access to industrial networks – (operational technology (OT) networks) from business networks (IT)) can enable and optimize digital transformation strategies, but how remains a challenge.

Improving Ethernet technology enables better coordination of OT and IT communications. Ethernet relies on a process of identifying collisions in communications and then covering after a wait time. While this is a good process for general purpose IT networks, it is not optimal for OT networks.

Traffic message sizes pose a challenge, and care must be taken to ensure a device doesn’t consume an inordinate level of bandwidth at any one time. While it would be great to improve all end devices on a network for conformance, an alternative would be to improve the Ethernet stan-

dard to “shape” traffic through frame preemption and prioritization. Ethernet also should offer time synchronization, enabling devices to schedule communications, avoiding communication collisions. Devices can coordinate communications for dedicated use. Precision timestamping is achieved at the nanosecond level of accuracy.

Five benefits to advanced Ethernet use

These Ethernet enhancements were started in 2012 by the IEEE 802.1 [Ethernet] working group. The first result was delivered in a new specification in 2018. Ethernet with time-sensitive networking (TSN) is very important for industrial automation applications. TSN brings five benefits:

• All OT devices are available from an IT network – Enabling improvements in analytics, asset management, and device management.

• Improved performance – The combination of scheduling, prioritization and greater bandwidth is resulting reliable, larger, and more complex applications.

• Simpler architectures – Resulting in cost savings and improved reliability.

• Troubleshooting ease – Users can leverage IT tools, such as simple network management protocol (SNMP), to interact with and manage devices.

• The long-term TSN benefit is improved cost effectiveness through new product delivery and market competition – Initial solutions focused on high performance applications. Over time, device vendors and infrastructure vendors have created compatible product offerings. ce

Thomas Burke is global strategic advisor at CC-Link Partner Association (CLPA), a CFE Media and Technology content partner. Edited by Chris Vavra, web content manager, Control Engineering, CFE Media and Technology, cvavra@cfemedia.com.

HOW TO AUTOMATE: VARIABLE FREQUENCY DRIVES

Kurt Niehaus and Will Young, Applied Control Engineering

Eight frequently-neglected VFD parameters to optimize

Recognizing variable frequency drives (VFD) parameters can help engineers get better performance for many applications.

Over the last century, electric motors have become ubiquitous for powering a variety of industrial devices, including pumps, fans, and compressors. In the last few decades, variable frequency drives (VFDs) have emerged as a powerful, and now common, tool for reducing energy consumption and optimizing control of electric motors. When setting up VFDs for industrial automation, its likely engineers worked with electrical contractor to ensure each VFD was adequately controlling its respective motor during commissioning. That said, electrical contractors are often not experts in optimizing the drive to the specific motor and application needs. Most modern VFDs are complex control devices include many parameters that can be fine-tuned to bring even more benefits to an application.

Eight VFD parameters

There are eight VFD parameters that often are not addressed during installation and often can be optimized to bring a number of improvements to the motors. For all the settings discussed in this series, first verify the parameter matches what is listed in the manufacturer documentation and paying particular attention to engineering units.

VFD parameter 1: Thermal current

The thermal current is a parameter that indicates the maximum allowable current, which is different than full load amps (FLA). While FLA is the rated power and indicates the maximum amps allowable for the motor long term, thermal current indicates a higher amperage that can be applied briefly, allowing the VFD to safely apply more than the motor’s standard rated power.

The thermal current setting informs the VFD how much “extra” power the motor can handle and operate without a thermal failure. When this limit is exceeded, the VFD can trigger a fault before a motor overload occurs, protecting the motor from thermal failure. When configuring the drive parameter for motor current, users can find the FLA and motor service factor (SF) on the motor nameplate. Multiply these two values to calculate the thermal current in amps.

VFD parameter 2: PWM

Every VFD powering an ac motor works by converting line ac power to dc, which the VFD then modulates into an ac waveform. This modulation is done by rapidly pulsing the DC power – turning it on and off – to create an ac wave. The VFD adjusts the wave’s amplitude and frequency to spin the motor at the desired speed. The pulse-width modulation (PWM) switching frequency parameter regulates these pulses and can be adjusted by changing the number of pulses used to create the ac powering the motor.

When PWM is not optimized for the motor and application, the dissipation of the heat produced by the motor and the drive is not balanced. If the PWM is too low, the motor will heat up faster, which is indicated by the motor screeching. Eventually, this can lead to issues with insulation breakdown and/or bearing pitting. A high PWM requires the drive to work harder, eventually overheating the drive and shortening VFD life.

An elevated PWM can increase the development of reflective waves between the motor and the drive, which can cause increased current induction in the motor shaft, resulting in bearing pitting in the motor and grounding faults in the drive. By correctly finetuning the PWM, users can balance heat displacement and extend the life of the motor and the drive.

controleng.com

KEYWORDS: Variable frequency drives (VFDs), discrete manufacturing LEARNING OBJECTIVES

Learn about the eight most common variable frequency drive (VFD) parameters that are often overlooked.

Understand how addressing these parameters can help manufacturers improve operations.

Learn about how engineers can improve user experience with graphical displays. ONLINE

https://www.controleng. com/discretemanufacturing/ motors-drives/ CONSIDER THIS

What are the most important parameters you consider for VFDs?

ANSWERS

KNOWING eight variable frequency drive (VFD) parameters can help optimize motor system operations for automation. Graphic courtesy: Control Engineering; Information courtesy: Applied Control Engineering

VFD parameter 3: Deceleration time

Deceleration time is the parameter that determines how long the VFD will take to slow down the motor. A longer deceleration time will lead to a longer ramp down to fully stop the motor. While many installers know to optimize acceleration time to prevent issues with over-current at start-up, the deceleration time tends to get overlooked.

‘An appropriate deceleration time will decrease the magnitude of electricity created by the slowing load and prevent a fault.’

Adjusting the deceleration time is important for preventing an over-voltage fault that can be created when power is removed from a motor and the inertia from the load continues to spin the motor. This rotation causes the motor to generate electricity, which is fed back into the drive, causing it to fault. In this case, an appropriate deceleration time will decrease the magnitude of electricity created by the slowing load and prevent a fault. For example, if users have a motor controlling a fan and it takes 10 seconds to decelerate and stop the fan, the drive should be programmed with this deceleration time to extend the life of the motor. Please note though, if a quick stop is required for process or safety reasons, additional hardware may be required and appropriate experts should be consulted.

VFD parameter 4: Minimum speed

The minimum operating speed is a speed setpoint, typically calculated as a percentage of maximum speed, below which the VFD will tell the motor to not run. Since most motors are cooled by an internal fan, which has a speed directly correlating with the motor speed, setting a minimum operating speed is important to prevent motor overheating that can occur at low speeds. For example, if the minimum operating speed is set to 10%, and someone provides a speed refer-

ence to the VFD of 5%, the VFD will not rotate the motor. Keep in mind the controls integrator should make sure this is taken into account in the implementation of any interfacing programmable logic controller (PLC) configurations, such as proportional-integral-derivative (PID) algorithms where the drive is controlled by the control variable (CV).

VFD parameter 5: Frequency jump

The frequency jump function typically consists of several parameters. The frequency jump parameters each denote a frequency at which the VFD will not run the load. Many mechanical systems have a frequency – or frequencies – at which the system will excessively – and possibly destructively – vibrate. For example, if a system has a resonant frequency of 40 Hz, it would excessively vibrate if the motor were running at 40 Hz, possibly shaking parts loose. By properly setting the frequency jump, the VFD will skip 40 Hz, and prevent these vibrations. While some equipment manufacturers may identify resonant frequencies, they are more commonly found by experience. There may be additional related parameters indicating a band, so there is a range the VFD will not dwell at.

VFD parameter 6: Graphical settings

Every major manufacturer offers a small programmable LCD human-interface module (HIM) with their drives. While the default settings may be appropriate for some applications, the module is generally programmable to show different values on the display or to customize the user experience. Three of the most valuable settings, display value, display units and password, are covered below, though parameter names may vary by VFD manufacturer.

1. Display value

Most VFD HIMs have a default factory setting to display the motor speed. Some applications are better served by displaying another value. For example, motor power will change in many mixing applications as the viscosity changes. Displaying the power on the HIM will allow an operator to determine how mixed the product is without bringing up a supervisory control and data acquisition (SCADA) display in a control room. The best way to determine the ideal display value is through knowledge of the process, the options, and plant

operators’ preferences. Depending on the manufacturer, an operator also could view frequency, current, custom messages, or a calculated value.

2. Display units

The value of the HIM can only be optimized if the right process information is displayed in the right units. In some cases, this is simply changing the display to show the value in metric units, such as liters/min instead of gal/min. In other cases, it may be aligning the value to match SCADA and HMI screens to show percent speed instead of RPM.

3. Password

The password and related settings can be used to limit operation of a VFD from the HIM. While limiting VFD operation might be for security reasons, there also are operational reasons to restrict control of a motor. For example, it may not be desirable to surprise an operator in the control room by turning on a motor from an HIM in the field. Many manufacturers’ password settings can lock out any unauthorized users, while retaining visibility on the display parameters. Determining the best use of these security measures is best done as a collaboration with plant and engineering personnel responsible for safety, security and operations.

VFD parameter 7: Controls, 4 settings

The control characteristics are a group of parameters that help define how the VFD will change frequency and power to meet the programmed setpoints in high-end drives. This can be essential for ensuring the correct amount of torque is applied at the proper time for the application. This is not to be confused with the settings for those setpoints that are always set up during commissioning. Most manufacturers provide several different control characteristic settings to help with the specific application, with the four most common being:

1. Volts per hertz (V/Hz): Controls the magnitude of voltage and current relationship. Good for fan and pump applications where flow is more important than pressure. Will maintain full torque range within about ½ of motor slip (essentially the lag of the stator behind the rotor) but may not be able to maintain torque below 2 Hz.

2. Sensor-less vector (SV): Provides higher starting torque and speed control within ¼ of

motor slip. Good for deep well pumps and high constant torque applications (autotune should be used when using this control method).

3. Flux vector (Open loop): Improves V/Hz by providing magnitude and angle control. By sensing the motor flux and orientation, this method provides more precise motor speed and torque control.

4. Closed-loop vector: This method uses a motor mounted encoder to provide shaft position and speed back to the drive. Using this method, a motor can develop full torque at zero speed. It is ideal for cranes and hoists. Some of these interact with each other, and others preclude the use of different parameters. For example, setting torque control settings negates the ability for auto-tune.

VFD parameter 8: Smart parameters

Today, many VFDs include a variety of “smart” features that can help further improve the efficiency and lifespan of the motor. However, since these features vary from drive to drive, we often see many of these features are underutilized. For example, some drives include sensors to monitor how much power is needed to produce a certain speed.

Some drives may also come with the ability to perform certain actions based on a trigger condition. For example, a drive connected to a pump may sense the pipeline is starting to experience a blockage based on the amount of power required to move the fluid through the pipe. The “smart” drive could be programmed to temporarily increase the power in an attempt to clear the pipe.

When these manufacturer-specific smart features are understood and implemented correctly, energy efficiency improvements and the ability to proactively perform some maintenance tasks is possible. When these features are set in conjunction with the control characteristics discussed above, users can even get more power out of the drive regardless if it’s operating at the low or high end. ce

Kurt Niehaus is manager of sales and Will Young is an engineer at Applied Control Engineering, a CFE Media and Technology content partner. This article appeared on Applied Control Engineering’s website in two parts. Edited by Chris Vavra, web content manager, Control Engineering, CFE Media and Technology, cvavra@cfemedia.com.

‘ Closed-loop vector control uses a motormounted encoder to provide shaft position and speed to the drive.’

Insightsu

Variable frequency drive (VFD)

uVariable frequency drives (VFDs) are a common and useful tool for optimizing electric motor control, but engineers often aren’t using them to their full strength.

uThe authors argue eight parameters such as thermal current, control characteristics, minimum operating speed are often not addressed during installations.

uAny VFD changes should comply with manufacturer documentation as well as its application.

ANSWERS

Gaining actionable insights with SCADA systems

SCADA software improves monitoring, control.

To succeed in the food processing sector, requires a balancing act of nuances among perishable ingredients, supply chains, production, quality control, and effective workflows along with proper reporting to ensure compliance with government and customer requirements. To ensure efficient and profitable operations, obtaining actionable insight into production is imperative. A way to achieve this is by using supervisory control and data acquisition (SCADA) and human-machine interface (HMI) software.

SCADA systems collect and analyze production data and deliver it to HMIs for intuitive visualization of real-time performance. These technologies allow companies to better monitor and control production. It can provide diagnostic and alarm capabilities for reduced downtime and waste.

It wanted to better understand the quantity of resources being used and tank levels to be able to order raw materials based on storage availability. Other requirements were to be able to identify potential efficiency gains in its manufacturing processes by investigating overall equipment effectiveness (OEE) and measuring key performance indicators (KPIs); to have the capability of batch management and material handling; to track quantity of additives for regulatory purposes; and monitor product quantities.

KEYWORDS: SCADA software

LEARNING OBJECTIVES

Understand how insights from supervisory control and data acquisition (SCADA) systems can help manufacturers improve operations.

Learn how a food and beverage company used real-time data from SCADA systems to improve operations.

ONLINE

See additional SCADA stories at https://www.controleng. com/control-systems/ dcs-scada-controllers/

CONSIDER THIS

What insights are you gaining from SCADA software?

With real-time performance data, companies can also adopt predictive and preventive maintenance capabilities which allows operations teams to make data-driven decisions about where and when maintenance should take place. It also offers improved traceability through the real-time tracking of production data. And, due to the nature of the food industry, it is essential to have operational flexibility and agility to ensure efficiency and scalability. This is especially important to help companies stay on top of the frequent changes that are common in this industry sector. A food manufacturing company improved production through use of real-time data insight driven by SCADA and HMI technology is Catania Oils.

SCADA data improves operations

Catania Oils is a manufacturer of non-GMO Project verified and organic oils for the ingredients, food service, and retail markets. The company needed help to use existing data to allow it to gain informational insight for plant-wide visualization into production and which lines are up and which are down.

The company wanted to capture data and generate meaningful displays to allow it to make datadriven decisions. Catania Oils went with a system integrator that chose to employ a web-based realtime HMI/SCADA suite with a plant data historian. The company can better monitor and control production, including OEE and loss deployment, to improve production efficiency. The key to improving operations was to focus the right resources on the actual problems and to use OEE for gaining insight. OEE provided a clear understanding of the difference between the quantity of sellable product that could be made versus the actual product that was made. The company made efficiency gains by monitoring loss deployment. SCADA software enabled Catania Oils to determine how much product has been made, the loss of efficiency attributed to the fault of a machine or asset, and the loss of efficiency attributed to the process for the asset.

By monitoring OEE and loss deployment, it has gained improved awareness into potential losses of efficiency. Using SCADA production data collected and displayed on the HMI system, the company can focus on the process, to gain greater efficiency. ce

- This originally appeared on Control Engineering Europe’s website. Edited by Chris Vavra, web content manager, Control Engineering, CFE Media and Technology, cvavra@cfemedia.com.

Kyle O’Brien, Omron

AMRs help eliminate manual processes in autonomous RFID inventory system

Self-navigating mobile robotic technologies, autonomous mobile robots (AMRs), can help support a variety of payloads and provide a foundation to verify contents of warehouse containers.

T&W Operations provides smart radio frequency identification (RFID) inventory products and looked automate all manual and forklift-dependent processes for shipping/receiving and warehousing. Building upon earlier versions, the company used autonomous mobile robots (AMRs) to replace all manual processes. Both applications — the shipping/receiving RFID system and the manufacturing RFID system are autonomous.

Heavy-payload AMRs with RFID, safe navigation enabled the company to build a complete, labor cost reduction solution for warehouses, improving accuracy and cleanliness in logistics and warehousing facilities while mitigating the challenges of today’s labor shortage. Key benefits of the new solution include:

• A hands-off RFID verification application. Whether it’s quality system checks, manifest generation, or another need, the AMRs facilitate an automated conveyor system.

• Mobile bases that safely carry heavy payloads. The AMRs have built-in safety features that can carry more than 3300 lb, including T&W’s expandable towers that reach up to 30 feet.

• Mapping technology that responds to obstacles in real time. The AMRs have self-navigating software that detects objects in the

way and finds the easiest way to get around them, ensuring safe movement around human workers.

Leveraging RFID with automation

T&W’s original Tower Inventory System (TIS) required a few manual and forklift-operated processes. To make it easier for customers to implement RFID-based content verification, the company used AMR technology as a foundation for the T&W Expandable Robotic Tower Inventory System (TIS-ER).

Two AMRs were used for the inventory system, one of which used the Omron LD-250, a mobile robot with a payload of up to 120 kg (265 lb). The system can expand to a height of 10 feet, all of which is mounted atop the LD-250 to operate in warehouses with inventory racks less than 10 feet tall.

For warehouses with higher racks, another version used the Omron HD-1500, a heavy-duty mobile robot with a payload of 1500 kg (3307 lb), which supports a system that can expand to heights of 30 feet. This provides benefits to warehouses with tall racks since all inventories can be scanned and analyzed in one sitting. While the AMR moves, the tower adjusts to varying rack and ceiling heights.

T&W also created an AMR-based product to help customers use RFID in the manufacturing space. The AMR is fitted with a powered conveyor that picks up containers while contents are

KEYWORDS: AMR, autonomous mobile robot LEARNING OBJECTIVES

Learn what autonomous mobile robots (AMRs) can do and are designed for in a manufacturing facility.

See examples of how they helped a company improve their logistics and warehousing.

ONLINE

See additional robotics stories at https:// www.controleng.com/ discrete-manufacturing/ robotics/

CONSIDER THIS

How can AMRs help in your manufacturing facility?

ANSWERS

FIGURE 1: The T&W Expandable Robotic Tower Inventory System (TIS-ER) uses Omron Automation

LD-250 mobile robot with a payload of up to 120 kg (265 lb) for a reach of 10 ft, and the Omron HD-1500 heavy-duty mobile robot with a payload of 1500 kg (3307 lb) for a reach of 30 ft. The mobile “tower” travels autonomously through warehouse aisles, collecting RFID tag data and communicating to the warehouse management system. Images courtesy: Omron Automation

FIGURE 2: T&W’s TIS-ER is designed to retrieve the container via the automated conveyor and proceeds to the RFID portal where the contents are again verified without human interaction.

validated against a contents database to ensure the package contains items needed for the next operation.

Once this operation is complete, the robot retrieves the container via the automated conveyor and proceeds to the RFID portal where the contents are verified without human interaction.

AMRs use navigation software and avoid obstacles to respond in a dynamic real-time environment

AMRs are designed to move autonomously through dynamic and peopled environments without requiring any facility modifications. After an initial “teaching” session in which an operator directs an AMR to create a map of the facility, the onboard self-navigating software will determine the best routes to reach a given destination and identify any unexpected obstacles in the way. AMRs can work as part of a coordinated fleet.

AMRs are easy to setup and are flexible for redeployment amid any changes to warehouse layout, maximizing space usage. Since they have built-in, safety-rated laser scanners and are programmed with safety settings that prevent collisions with obstacles (including humans), they can operate in close proximity to human workers and other equipment to decrease risk of injury or damage.

The AMR-based products also help maintain cleanliness while maintaining 100% inventory accuracy by eliminating human interaction. They let warehouse associates to engage in more fulfilling and creative tasks by leaving routine contents verification work to an autonomous system. ce

Kyle O’Brien is industry manager – logistic at Omron Automation. Edited by Chris Vavra, web content manager, Control Engineering, CFE Media and Technology, cvavra@cfemedia.com.

u

Insights

Autonomous mobile robots

uAutonomous mobile robots are designed with built-in safety features that can carry large amounts of weight and are useful in logistics and warehousing operations.

uAMRs are designed to move autonomously through dynamic and peopled environments without facility modifications after being taught by a programmer.

John Livingston, Verve Industrial

Attack surface management: Six steps for success in OT/ICS

For operations technology (OT) and industrial control systems (ICS)

cybersecurity, reduce risk by managing the attack surface. See six steps: Discover, assessment, context, prioritization, remediation, maintenance.

Over the past two to three years, enterprises have realized the critical importance of attack surface management (ASM) to identify, prioritize and minimize the potential threat vectors in their environment. Besides the general growth in attacker activity, the largest driver of this need is because organizations’ attack surfaces have expanded so much in the past five years or so. And those “surfaces” are often unmapped and unknown – sort of like the “unknown” parts of the world prior to the Western explorers’ “discoveries.”

Cloud and software-as-a-service (SaaS) were the initial obvious causes of attack surface expansion – and were what drove the initial push to manage these unknown dominions.

However, as operational technology (OT) systems – industrial control systems (ICS), building controls, transportation controls, etc. – become more connected in the drive for greater efficiency and effectiveness of production, OT and internet of things (IoT) now become the “new frontier” of the attack surface management challenge. In fact, according to a 2021 survey of CISOs and senior cybersecurity leaders, the number 1 challenge of current ASM initiatives is the identification and management of OT/IoT and other unknown systems.

Most attack surface management tools and approaches do not understand the technical complexities and operational requirements of these OT systems. But there is a way to effectively and efficiently conduct ASM in OT.

What is attack surface management?

Attack surface management is the continuous discovery, collection, assessment, classification, prioritization, remediation and monitoring of IT/OT/ IoT assets. This may sound like traditional asset inventory or vulnerability management. However, ASM takes an “attacker” view of the challenge. This approach adds significant value to more traditional vulnerability management approaches because it helps to prioritize those risks that are most likely to create a threat from attackers. When done correctly, it allows an organization to prioritize their most critical exposures – not just based on a CVE score,

FIGURE 1: Verve Industrial research finds financially motivated ransomware to be the biggest threat, followed by nation-state threats, and devices added to the network. Images courtesy: Verve Industrial BEST

FIGURE 2: A full 360-degree view needs to include important context about an asset, described as “asset criticality/impact” in the chart.

but based on the true potential for a critical event from an attacker.

Six elements of OT attack surface management

OT attack surface management includes 6 key elements:

lar reviewing of threat vectors to identify new risks and continually update current risks based on the remediation actions taken and new vulnerabilities identified.

1. OT attack surface management challenge

This six-step process sounds easy, but many organizations find difficulties at various steps along the journey. This is particularly the case for industrial organizations that have significant OT footprints. Many organizations have discovered that traditional vulnerability management or threat detection, especially in the OT world, creates resource burdens that are just not feasible.

‘ Remediation is challenging because of the age of many systems and

the

inability to update those systems. ’

1. Discovery: The ability to see all “corners of the world” of your attack surface. This includes the discovery of unknown assets, unknown connectivity (both actual flows and potential flows due to misconfigured network devices), software, configurations, users, etc.

2. Assessment: Identifying the risk of an asset based on a 360-degree risk assessment that includes all elements of the discovery – users and account access, network access, software and hardware vulnerabilities, missing patches, insecure configurations, etc.

3. Context: This adds an overlay of criticality, usage, owners, etc. to create a risk profile of the asset as it relates to an attacker’s perspective.

4. Prioritization: This is where ASM truly differs from vulnerability or inventory management. ASM prioritizes risks based on the attacker’s perspective using the above information. The eventual result is a risk score that takes into account the various elements to prioritize actions.

5. Remediation: The consistent hardening of security directed by the prioritization in the prior step. This includes comprehensive actions such as network protection, patching, hardening, etc.

6. Maintenance: Perhaps the hardest part of the entire process is the ongoing updating and regu-

In OT, the first challenge is just getting an accurate “map” of the attack surface. The traditional approach of manual or network-span port inventories just does not provide an accurate “map of the world,” so to speak. It misses assets, incorrectly identifies vulnerabilities and leaves an organization with no ability to immediately take remediating actions. Further, much of the OT threat detection creates huge volumes of alerts with little specific attack surface insight to prioritize those alerts.

Remediation is challenging because of the age of many systems and the inability to update those systems, therefore requiring a more holistic approach to the remediation actions. Finally, most organizations do not have a true “enterprise” view of their OT surface – the information is often stuck at the plant level, which makes resourcing and prioritization very challenging.

Recent attacks focused on IT that crossed over into OT systems are an example of this lack of true visibility. Ransomware is now the No. 1 concern of OT security practitioners, according to the 2021 SANS survey; it wasn’t in the top five two years ago.

That threat vector – coming through the information technology (IT) side and bridging into OT –is part of a company’s attack surface that is often not seen completely. Once through that connection, the attack surface within the OT environment usually has many “dark spots” where light doesn’t shine.

Mandiant’s research shows that 99% of all attacks start with and leverage the IT-type infrastructure that sits between IT and OT. These connections are often not well understood. In our own research, Verve finds that misconfigured firewalls, dual-

NICs bridging networks, individual programmable logic controllers (PLCs) and other devices connected directly to the corporate network are present in almost every plant we assess. There is a lack of view of that surface.

2. Succeeding in OT ASM

Attack surface management is possible in OT, but it requires a fundamentally different approach than most organizations or ASM providers take today. There are six key steps to getting this right:

Successful discovery: Capturing endpoint and potential network connections accurately and comprehensively.

On the IT side of the house, if the team came to the chief information security officer (CISO) and said the only way to discover the attack surface is to gather manual inventories or observe network traffic, the team wouldn’t last long. IT uses scanning, agents, discovery tools, as well as manual and network approaches to capture a full picture of its attack surface. But in OT, because of the sensitivity of these devices, security leaders have been left with less than effective options.

There is an OT-safe and more effective alternative, however. Control systems engineers interact with their systems every day to program, backup and tune. These same techniques can be used to discover the full view of the attack surface. Using an endpoint-focused approach to asset inventory rather than a network approach allows for a much broader view into all of the corners of the map, but it also allows for a deeper view of each potential asset. This endpoint approach discovers not only that a device exists, but also all of its users, accounts, software, patch status, firmware versions, configuration sta-

tus, possible (not just actual) network paths, antimalware status, etc.

360-degree assessment: A platform that allows for a comprehensive risk view.

An effective assessment must include a comprehensive view of the risk to each asset. That should take into account all of those findings from the complete discovery described above. A 360-degree view allows the organization to make appropriate trade-offs in risk priority.

3. Adding important context: Asset criticality and use is key to future prioritization.

As figure 2 chart shows, a full 360-degree view needs to include important context about an asset, described as “asset criticality/impact” in the chart. To conduct the next step of prioritization effectively, the attack surface needs to include robust context from the criticality of the asset, its use, its network connections to other devices, etc. In some cases, organizations will have some of this data available from other efforts, such as disaster recovery analysis. But in others, this context needs to be created from the data provided based on the connections, software installed, etc.

4. Effective risk prioritization: Don’t get overwhelmed by all of the potential risks you see.

One of the biggest challenges in OT security is the number of risks found in many of these environments. In most cases, OT systems aren’t patched regularly, older devices run out-of-date firmware, the anti-malware status may not be regularly updated, etc. In most assessments, our platform identifies

FIGURE 3: Thinking global includes scaling analysis in a central program, leveraging regional subject-matter experts (SMEs) and acting with local operations control over actions.

controleng.com

KEYWORDS: Attack surface management (ASM), industrial control system (ICS) cybersecurity

ASM is the act of identifying, prioritizing and minimizing threat vectors in a business environment.

The elements that ASM have are discovery, assessment, context, prioritization, remediation and maintenance.

Industrial Cybersecurity Pulse, a CFE Media and Technology online site, published this Nov. 7, 2022.

CONSIDER THIS

How could this 6 steps make your industrial control system more secure?

ONLINE https://www. industrialcybersecuritypulse. com

‘ The discovery of a threat is irrelevant if you can’t respond rapidly and safely for OT. ’

thousands of critical vulnerabilities. There’s no way an organization can get to all of this immediately.

Key to threat surface management in OT is to prioritize the risks to remediate first. These risks should begin with those most likely to be used by an attacker and to have significant impact on the environment. This should balance the exploitability of a vulnerability with the extent that the attack could spread to critical assets across the environment. The only way to do this effectively is to bring all of the data into a single database across original equipment manufacturer (OEM) systems, endpoint and network risks, operational impact, etc. An effective OT ASM platform needs to enable all of that.

We also would argue that in OT, a key to this prioritization is to integrate the database with human analysts that can help the organization bring insights from other entities and threat data to help prioritize. This “man and machine” approach offers the greatest source of prioritization.

5. Rapid and safe remediation management includes management

The discovery of a threat is irrelevant if you can’t respond rapidly and safely for OT. In IT, organizations will focus on weekly updating of patches, automated resetting of configurations, network access

Great obstacles to resolving control system cybersecurity vulnerabilities

control to refuse connections from unknown assets, etc. In OT, however, many of these solutions can cause an operational impact on the processes you are trying to protect. As a result, in OT, many of the solutions to date have focused on detection only. They will focus on anomalous patterns of network behavior that you may want to address.

An effective OT ASM platform needs to enable both the prioritization of risks and the ability to immediately pivot to remediation in a way that’s efficient and safe for the processes. This requires an OT-safe management platform that allows you to patch, harden configurations, remove unapproved software, remove or limit access for certain accounts or users, create network segmentation, etc. The most efficient way to do this is to integrate it into the ASM platform rather than rely on separate tools or manual efforts to conduct each of these different remediation actions.

The best way to think about this is what we call “Think Global: Act Local.” This architecture enables centralized analysis and prioritization of remediation actions but also ensures that when actions are actually executed, they are controlled by those closest to the process such as DCS engineers. This balances the need for efficiency and OT safety.

6. Efficient maintenance:

Reduce labor requirements by 70-plus%.

The No. 1 challenge of OT security is resource constraints. Industrial operations personnel are already overwhelmed – even before the great resignation of the past couple of years. This stress on resources is amplified when you overlay security knowledge on top of this. This is seen in survey results such as the KPMG-CSAI survey of control systems security personnel shown below.

The “Think Global: Act Local” approach above also allows an organization to radically reduce the costs of maintaining the attack surface. We find that many organizations are relying on local site personnel to manage their OT security. It is a feasible approach for consistency and labor efficiency. ce

John Livingston is CEO, Verve Industrial. Edited by Gary Cohen, content manager, Industrial Cybersecurity Pulse , CFE Media and Technology, gcohen@cfemedia.com.

BEST OF INDUSTRIAL CYBERSECURITY PULSE

Daniel E. Capano, Gannett Fleming Engineers and Architects

Throwback Attack: How Stuxnet changed cybersecurity

Are we doomed to repeat the past? What have industrial control system users learned about Stuxnet to help in their cybersecurity efforts?

Hints: Airgaps aren’t foolproof. Targets can include the unintended. Evaluate and remediate vulnerabilities once discovered.

During the second Bush Administration, there was great concern about the rapid progress of the Iranian enrichment program, which would likely lead to the attainment of weapons-grade uranium. The center of that operation was, and is, the Natanz Laboratory located in the middle of the desert about 33 km from civilization.

The facility, technically known as a “fuel enrichment plant,” is one of 17 other Iranian nuclear facilities. It uses centrifuges to concentrate and separate U-235 from uranium hexafluoride gas. The facility was planned to operate 19,000 centrifuges. Natanz is air-gapped, in that it is isolated from the outside world. The underground processing facility is heavily fortified, covered by 22 meters of earth, and was designed to be impregnable, both physically and electronically.

Malware worm intended to cause harm

Code-named “Olympic Games,” an effort was begun to avoid a direct conflict with Iran. Olympic Games was a collaboration (still unacknowledged) between U.S. and Israeli intelligence and was part of a larger effort to infiltrate and disrupt Iran called “Nitro Zeus.” Out of this operation came the malware known as Stuxnet (a combination of keywords .stub & mrxnet.sys).

Stuxnet, technically a worm, is the first known offensive cyberweapon specifically designed to

inflict damage on equipment in the real world. It is worth noting it was not the last purpose-built offensive malware; had there not been a flaw in the code, the world may never have heard of it. It escaped into the wild sometime in 2010, infecting thousands of computers worldwide with what was generally referred to as “the bug.”

Operation Olympic Games

Stuxnet takes advantage of what are termed zero-day vulnerabilities. Zero days are unknown vulnerabilities in software that threat actors use to infiltrate and exploit unpatched operating systems. Stuxnet used four zero-day vulnerabilities to infect the Microsoft Windows operating system. Zero-day vulnerabilities are very valuable to hackers, so the use of four of them was unusual, if not unprecedented.

Once injected, the code used other vulnerabilities to replicate and spread throughout the industrial control systems (ICSs) monitoring and controlling the centrifuge operations. The worm installed rootkits, allowing complete control of the operation; Stuxnet is the first known use of programmable logic controller (PLC) rootkits. Command and control of the worm were done through two websites located in Denmark and Malaysia, though these were not used after the initial stages of the operation. The worm also used stolen digital certificates for many drivers to allow it to appear legitimate.

ANSWERS

STUXNET helped elevate cybersecurity to a global concern. Courtesy: CFE Media and Technology

‘ The underground processing facility was designed to be impregnable, physically and electronically.’

There has always been some mystery behind how the worm was deployed at Natanz. The prevailing theory was infected USB drives were planted at venues frequented by the Natanz technical staff, as one of the zero-day vulnerabilities allowed loading of malware from a USB drive without notification to or interaction with the operating system upon insertion. This method was used later in the operation but in a different way. Initially, the Dutch intelligence service, AIVD, in collaboration with the Israeli intelligence service, Mossad, used established moles and a front company in Iran to insert the malware into the air-gapped systems on-site. This was the result of several years of intelligence gathering at the facility.

Proof of concept closed discharge valves

Germany also supplied technical data on the ICSs that controlled the centrifuge operation. In addition, a shipment of centrifuges, identical to those being used at Natanz, was seized by the U.S. on its way to Libya. These centrifuges were reassembled at Oak Ridge and in Israel – and were subsequently destroyed by an early Stuxnet prototype.

The parts of a destroyed centrifuge were famously dumped on the conference table in the White House situation room as proof of concept of their plan, which got them the green light to proceed.

The worm was initially designed to close the discharge valves of the centrifuges to create overpressurization and waste gas – the centrifuges operate in a vacuum, and the gas solidifies at low pressures — instantly destroying the centrifuge. This method wasn’t too effective; the Iranians found a workaround, and damage was limited. This version of the worm was updated on-site several times as more operational data was observed by the mole and reported back to the consortium.

At this point, the mole lost access to the facility for reasons unknown; it’s also possible the mole did not need access any longer. Concurrent to the on-site injection operations, several Iranian contractors performing work at the facility were compromised or their computers were infected with the second version of the worm.

It is likely the newer version of the worm was delivered by these unwitting employees using the planted USB drive method; however, it would have been easier to infect the contractor’s internal networks. The worm does not attack computers, rather, it was designed to attack supervisory control and data acquisition (SCADA) software and PLCs. There was a hitch: To ensure the worm spread efficiently, code had been written to take advantage of several spreading methods, which made it promiscuous and caused it to go wildly out of control. It spread to several of the contractor’s other clients and then to the world. Unfortunately, several of the contract employees were arrested and executed for introducing the worm into Natanz.

The Stuxnet attack

Stuxnet is a very sophisticated piece of software. It is estimated that a multinational team of coders took up to three years to develop the worm. This, of course, included feedback from the Dutch mole, which allowed the team to fine-tune and develop a different attack method. Key to the attack was the ability of the worm to monitor and record normal operating data. The operator saw what looked like normal operating parameters on the human-machine interface (HMI) screen while the centrifuge was operating adversely.

The worm ran silently in the background, recording operating data and storing it in hidden files the mole downloaded and then sent back to the programming team. This data was analyzed, and in concert with the data gleaned from the operating centrifuges in Oak Ridge and Israel, an attack vector was designed and the code modified.

The worm was designed to infect the SCADA software files and compromise PLCs that controlled the centrifuges’ rotational speed. The centrifuges normally spin at a rate of 63,000 RPM; due to manufacturing defects, however, the Iranians ran the centrifuges at about 4,000 RPM lower to avoid cracking the rotors. The actual attack was silent and autonomous. While the operators observed normal operation on their screens, the worm brought the centrifuges almost to a halt and then ran them rapidly up through the critical intermediate speed of 59,000 RPM to 40% over normal operating speeds, or 84,000 RPM. This alternation between low and overspeed conditions created significant vibration in the rotor and rotor bearings, which essentially destroyed themselves after a few cycles. This method effectively destroyed more than 1,200 centrifuges but did not significantly delay the enrichment program.

Rotating equipment anomalies

As one commentator describes it, the Iranian operators could not mistake what was happening despite what they were seeing on their screens. Centrifuges spinning at their rated speeds have a characteristic noise signature. At 59,000 RPM, the centrifuge sounds different than one running at 84,000 RPM. Anyone who has spent time in a plant with large rotating equipment for any length of time can hear whether or not the machine is operating properly. Experienced technicians can hear a failing bearing or other mechanical anomalies simply by listening. This is speculated to be the primary reason why Stuxnet had limited effect. After numerous failures, the technical staff had to do a full-court press diagnostic program involving all means of detection and troubleshooting. This would also include a full-scale audit of the controlling software.

While this may seem obvious in 2021, these were uncharted waters in 2010. It should be noted there was no expectation of anyone using an

‘ Stuxnet, technically a worm, is the first known offensive cyberweapon specifically designed to inflict damage on equipment in the real world. It escaped into the wild sometime in 2010, infecting thousands of computers worldwide.’

offensive cyberweapon for any purpose. It only existed in concept, or so we thought.

The counterattack: Shamoon

The Iranians quickly dissected the code and determined with reasonable certainty that the U.S. and its allies were behind the cyberattack. The escape of the code into the wild had allowed several firms, most notably Symantec, to reverse engineer the code and report their findings to the technical press. The United States and Israel were immediately identified as the perpetrators, but this has never been confirmed by either country. It was reported the parties involved were the National Security Agency (NSA), Central Intelligence Agency (CIA) and Mossad, specifically Unit 8200, their signal intelligence (SIGINT) branch.

Following discovery of the Stuxnet attack and attribution in the technical press, Iran embarked on an aggressive counterattack involving businesses and critical infrastructure in both countries and launching suspected attacks on facilities in allied countries.

For example, ARAMCO refineries were hit by the Shamoon virus, which wiped data from 30,000 computers. Intellectual property (IP) was stolen from numerous businesses and universities by suspected Iranian hackers.

Perhaps the best example of determined threat actors was Iran’s attack on critical infrastructure that was not only a harbinger of things to come, but also provided some unintended comic relief.

Mistaken target in counterattack

The Arthur Bowman Dam in Oregon is 245 feet high and 800 feet wide, impounding 233,000 acre-feet of water for irrigation purposes. It was targeted by the Iranians in 2013 in response to the Natanz attack.

controleng.com

KEYWORDS: Cybersecurity throwback attack, Stuxnet

LEARNING OBJECTIVES

Stuxnet, apparently designed for a specific target, caused issue well beyond the original intent.

Normal on-screen activities may mask what’s actually happening.

This was published Sept. 30, 2021, on the Industrial Cybersecurity Pulse website. CONSIDER THIS

Have you applied lessons learned from this throwback attack?

ONLINE

https://www.industrialcybersecuritypulse.com https://www.gannettfleming.com/

Iran’s Revolutionary Guard Corps used commonly available tools to seek out vulnerable critical infrastructure. Their attack followed the classic steps of reconnaissance, assessment and deployment. Their reconnaissance used Google. There are several search techniques and syntax that are called “Google Dorking.” They turn Google from a simple search engine into a powerful research tool. The next tool in their arsenal is Shodan, a specialized search engine that seeks out ICSs connected to the internet. Shodan is constantly being updated with internet-facing SCADA and standalone control systems.

‘

The worm was designed to infect the SCADA software files and compromise PLCs that controlled the centrifuges’ rotational speed.’

Another very useful tool was social media. There is a treasure trove of personal and professional data to be mined at sites like Facebook and LinkedIn. Finally, common IT and auditing tools like ICMP and SNMP were also used. What the Iranians attacked instead was the Bowman Avenue Dam in Rye Brook, New York. The Bowman Avenue Dam is 20 feet high and 50 feet wide, impounding the flood stage of the Blind Brook. The Iranian team found an unsecured wireless modem that would have been used to control the dam’s slide gate remotely (it was not connected to the gate’s control system). It is speculated this was the attack vector for the Arthur Bowman Dam; the dam gates would have been opened or closed to cause flooding or overtopping – either would have been a problem, though loss of life was not likely.

In their assessment, they neglected to do on-the-ground reconnaissance. This led to a high-profile failure for them, but it still served as a wake-up call. It showed any facility can be attacked. This was the beginning of cyberwarfare.

Stuxnet epilogue: Cyberwarfare

In the wake of Stuxnet, it is speculated that the same international team continued to exploit vulnerabilities in Iranian control systems. Three vari-

ants, known as the “cousins of Stuxnet,” shared much of Stuxnet’s code but were relegated to information-gathering roles. Duqu, Flame and Gauss are variants that while only information-gathering, are thought to be similar to Stuxnet but have not been activated.

Cyberwarfare is now the preferred way of conducting conflict between nation-states. While Stuxnet and its cousins ushered in the era of cyberwarfare, this sea change in international relations has been overshadowed by the recent wave of ransomware attacks that have targeted critical infrastructure. One ominous occurrence occurred in Florida in February [2021], where an attack on a water treatment plant was thwarted; this attack was similar to an attack on an Israeli water treatment facility.

As the paradigm for international relationships shifts from open, physical conflict to virtual warfare, it is imperative we begin to recognize we are all responsible for not only our own security, but for the institutions we rely on for our way of life. ce

Daniel E. Capano is senior project manager, Gannett Fleming Engineers and Architects, a CFE Media content partner and is on the Control Engineering Editorial Advisory Board. Edited by Chris Vavra, web content manager, CFE Media and Technology, cvavra@cfemedia.com.

Continued from page 11

System Integrator of the Year experts

Presenters during the webcast, from the firms named 2023 System Integrator of the Year, are:

- Tyler Graham, director business developmentdigital transformation, and Randy Rausch, director of technology-digital transformation, Eosys

- Mike Howard, vice president of system integration at George T. Hall

- Matt Lueger, executive vice president, NorthWind Technical Services.

Research on most-useful automation, automation advice, pain points

Learning objectives for the webcast are to:

• Review Control Engineering research about what automation and control technology topics are most useful.

• Understand system integrators’ views and advice about applying and advancing by implementing or upgrading applications using those automation and control technologies.

• Prioritize what to do first based on your pain points and business needs.

• Hear examples and best practices related to those technologies.

What next generation automation technologies will help in 2023

Impactful technologies for controls, automation, and instrumentation implementation in 2023 include:

Eosys: Artificial intelligence and machine learning, ontologies and graph databases and eventdrive architectures.

George T. Hall: Version control for programmable logic controller (PLC) programming, augmented reality (AR) and software conversion applications.

NorthWind Technical Services: Advanced analytics, mobile workforce and more robotics.

For more information and explanations view the webcast. Those listening live have the opportunity to ask automation implementation questions of the presenters. ce

Mark T. Hoske is content manager, Control Engineering , CFE Media and Technology, and moderator for this webcast, mhoske@cfemedia.com.

The voice of the engineering community speaks loud and clear in the following pages featuring the corporate profiles for companies participating in the 2023 Executive Voice program.

We offer our sincere thanks to these advertisers:

Electronics Endress + Hauser Inc.

Automation

Electric Automation, Inc.

controleng.com

KEYWORDS: Control Engineering webcasts, how to automate, important automation technologies for 2023

Jan. 18 Control Engineering webcast, archived for a year, identifies leading technologies important for automation, controls and instrumentation implementations in 2023. Webcast, called “Automation Series: How next-generation automation will help in 2023,” will be archived for a year.

CONSIDER THIS

What technologies will help you optimize automated processes in 2023? ONLINE https://www.controleng. com/webcasts/automationseries-how-next-generationautomation-will-help-in-2023/

In 1985 Advanced Micro Controls, Inc. (AMCI), began manufacturing PLC based controls in a house located in Washington, CT. Today AMCI has grown to be a globally recognized company and one of the world’s leading suppliers of industrial control solutions. Our close long term partnership with our customers is our hallmark.

AMCI products not only improve PLC-based automation systems with specialized position sensing and motion control technology but also simplify automation and add reliability to the manufacturing processes.

design and production process work hand in hand to deliver you the most efficient and reliable products in a timely and effortless manner.

AMCI began by developing the unique technology to interface the resolver rotary sensor directly into the Allen Bradley PLC system. Out of this partnership grew an extensive product line that was designed to endure the harshest industrial environments. To this day we are the only company to design and manufacture the actual resolver sensor in all of our transducers, providing a complete system that is 100% guaranteed to work together.

The PLC motion programming requirements learned from our early projects proved useful for the future motion product line. By putting our products on the network we increased use, lowered costs, and simplified installation, especially for distributed applications.

“Our design and production process work hand in hand to deliver you the most efficient and reliable products in a timely and effortless manner.”

Our engineering team designs a dependable, quality product that is manufactured in house, enabling superior quality and innovation. With our core team of engineers onsite, our

Today, with our E2 technology, our PLC Network Products provide access to Ethernet/IP, Modbus TCP, EtherCat, Profinet, and Profibus. This innovative multi-protocol approach for PLC

William Erbs President, AMCI

Industrial Ethernet networking, features dual port networking, PLC Programmable, and a web server.

Every day our experienced Sales Department assists customers in identifying the AMCI control products best suited to their application. Going beyond price, our Applications Engineers evaluate systems’ compatibility, installation, maintenance, and reliability when reviewing control solutions. We have a strong commitment to our customers that does not end with an invoice. AMCI provides 24/7 technical support staff, ready to answer questions about installation, configuration and operation of all AMCI products.

Our goal at AMCI is to deliver our customer a quality product along with quality service. We pride ourselves on our products knowing that your purchase will provide you with a reliable solution for many years to come.

Since its inception in 1983, Advantech has steadily grown for four decades, focusing on creating innovative technologies to improve our lifestyles and our environment. At this milestone year, Advantech would like to take this opportunity to thank our employees, our customers, and partners who helped us become a celebrated global brand.

Celebrating 40 Years of Innovation

Looking back on Advantech’s 40-year globalization development, from the establishment of overseas branches and the growth of a multinational enterprise, to the execution of a Globally Integrated Enterprise for strengthening the management matrix, the next era of globalization transformation will be powered by a Sector Driven growth model that creates a paradigm shift of growth for Advantech. Today, Advantech has offices in 28 countries, employs over 8,800 people and offers over 1,500 standard products.

Employees gather to proudly celebrate the Advantech 40th anniversary milestone.

KC Liu, Chairman of Advantech, “deeply believes that if a company only focuses on maximizing stakeholders’ profit, it will be unable to deliver sustainable innovation.

One of Advantech’s core product lines is Industrial PCs (IPC), which we first introduced in 1990. Within six months, five engineers created the IPC-600, a rackmount chassis to integrate the system. Many IPC’s found in the market today share a resemblance to Advantech’s 1st Industrial PC. Today, Advantech is the world’s largest supplier of Industrial PCs with 41% worldwide market share.

We plan to continue being a leader and innovator in this industry, working closely with our business and eco-partners to stay true to our mission of Enabling an Intelligent Planet.

“ The best way to maintain competitiveness is to combine the interests of the community, employees, clients, and shareholders.”

The best way to maintain competitiveness is to combine the interests of the community, employees, clients, and shareholders. In this way our corporate values can truly become altruistic and keep the company moving forward and growing, thereby setting the foundation for a sustainable future for another four decades.”

To celebrate our 40th anniversary, Advantech will bring employees and partners together and host events throughout the year. Please contact your Advantech representative for further details.

Linda Tsai

President, Advantech IIoT Group

Global electronics distributor

Digi-Key Electronics offers more than 13.4 million electronic components and automation products from over 2,300 quality name-brand manufacturers. The company’s reputation extends worldwide as the provider of the widest selection of electronic components in the industry, ready for immediate shipment. With products available in both design and production quantities, Digi-Key is the best resource for designers and buyers alike.

use of digital tools, industry leading supplier partnerships, and a breadth of product that is unrivalled by any other, Digi-Key paves the way as a one-stop shop to serve customers in a unique automation landscape.

Digi-Key is the preferred supplier for industrial automation, control and safety products, carrying a broad portfolio including advanced controls like PLCs, HMIs, motion, safety and robotics.

Digi-Key is a $5 billion company and employs more than 5,200 people, delivering over 27,000 packages per day to customers in 180 countries around the world.

The key differentiators of service that made Digi-Key who they are today, have laid the foundation for what Digi-Key brings to the world of automation tomorrow. Through the

Digi-Key provides detailed technical resources and robust search functionality to help you find the exact parts you need, including a range of EDA and design tools, reference design library and free online schematics tools, on-demand multimedia library, comprehensive article library and community forums, and much more.

Digi-Key’s Marketplace gives customers access to even more products and services, benefiting applications such as industrial automation, test and measurement, IoT solutions, and virtually all things related to technology innovation.

In 2022, Digi-Key opened its new, 2.2 million square foot Product Distribution Center expansion to meet and exceed customers’ expectations more efficiently.

Dave Doherty President, Digi-Key Electronics

Digi-Key provides numerous Supply Chain solutions, including eProcurement options, bonded inventory and just-in-time shipping. The website is updated regularly with new features in response to customer feedback and industry needs.

Digi-Key has also invested in innovations including cut tape printing, providing more products and services within the ecosystem and expanding the Digi-Key Marketplace.

Digi-Key provides the best possible service to customers, 24/7/365 by phone, email or chat. From prototype to production, Digi-Key has the resources and products to enable the world’s ideas!

1-800-344-4539

sales@digikey.com

www.digikey.com/automation

“ With products available in both design and production quantities, Digi-Key is the best resource for designers and buyers alike. ”

Digi-Key’s Product Distribution Center Expansion (PDCe) opened in 2022

Endress+Hauser, a global leader in measurement instrumentation, provides process solutions for flow, level, pressure, analytics, temperature, recording and digital communications. They optimize processes in terms of economic efficiency, safety and environmental impact and have been serving the US market since 1970.

In 2021, Endress+Hauser opened a new campus in Houston, Texas to better serve the Gulf Coast region. This state-of-the-art 112,000 sq. ft. facility sits in the heart of the Gulf states, bringing instrumentation, services and solutions close to customers.

The facility is equipped for training courses, repair services, and calibration. Endress+Hauser support teams, including inside sales and application engineering teams, provide localized technical expertise for customers. The training services include a PTU® (Process Training Unit) where trainees, technicians, and even local students can learn about IIoT capabilities, Bluetooth-enabled devices, instrumentation, and controls and much more. The campus also houses our area sales and service representative Vector Controls and Automation Group and Analytik Jena, an Endress+Hauser company.

“ The investment into the expanded service capabilities at this campus only affirms our presence in the Gulf Coast region and further strengthens our ability to serve local customers and the Texas community, today and into the future.”

Brian Walker, Vice President of Service

Instrument calibration is an important part of any process and Endress+Hauser brings that calibration expertise to the market. The expanded calibration facility at the Endress+Hauser USA Houston campus now features a calibration rig that services several different types of flowmeters, including meters from third party vendors and has expanded line size and flowrate capabilities. The calibration rig expands capabilities to a 12-inch line size and 1,750 gallons per minute and can service Coriolis (standard and premium calibration), electromagnetic, vortex, ultrasonic in-line, and ultrasonic clamp-on flowmeters.

This facility also provides meter cleaning services and remains an accredited calibration lab to help customers stay in compliance, while reducing costs and increasing uptime.

Expert local sales and service representatives are also a key part of the Endress+Hauser offering. With a growing network of local sales and service representatives, customers can leverage their partnership for product and application expertise.

Recently, four Endress+Hauser sales and service representatives added new mobile calibration rigs to their offerings to provide quick and easy on-site calibration. This dedication to calibration excellence has resulted in a fleet of mobile calibration trailers that can travel cross-country, making calibration easily accessible for any plant, no matter the location.

Brian Walker Vice President of Service at Endress+Hauser USA

Ignition: The Unlimited Platform for SCADA and So Much More

The Ignition industrial application platform combines unlimited licensing, instant web-based deployment, and the industry-leading toolset for supervisory control and data acquisition (SCADA) — all on one open, scalable universal platform.

More than just SCADA, Ignition is a great solution for the Industrial Internet of Things (IIoT), manufacturing execution systems (MES), humanmachine interfaces (HMI), alarming, reporting, and edge computing, all across the enterprise.

Ignition IIoT - This end-to-end IIoT solution lets you easily connect to and push data from thousands of devices across numerous sites through a central MQTT infrastructure to both industrial and business applications.

Ignition MES - Collect all your industrial data, connect to any SCADA or ERP system, and build virtually any MES application. Ignition tracks production, eliminates downtime, schedules work orders, manages recipes, and more.

Ignition HMI - Rapidly develop high- performance HMIs that optimize operator efficiency. Ignition makes working with HMIs easy, and updates are fast and painless.

Ignition Alarming - Build advanced alarming systems with drag-and-drop ease. Fast to install, easy to use, and infinitely scalable, Ignition is an unbeatable alarming solution at an incredible price.

Ignition Reporting - Easily create dynamic, database-driven industrial reports for a low price. Easily pull together all your data and create any kind of industrial report in any major format and automatically deliver it to anyone.

Ignition Edge - Ignition Edge is a line of lightweight, limited, low-cost Ignition solutions made for embedding into edge-of-network field and OEM devices.

Now you can extend data collection, visualization, and system management out to the edge of your network more easily and affordably.

Ignition Enterprise - Empower your teams, gather better data and drive smarter decisions.

As one central hub for everything on your plant floor, Ignition can easily control processes, and track, display, and analyze data, for your enterprise.

To learn more about what you can do with Ignition, please visit: inductiveautomation.com.

“ More than just SCADA, Ignition is a great solution for the Industrial Internet of Things (IIoT) ”

inductiveautomation.com info@inductiveautomation.com 800-266-7798

Inductive Automation’s corporate headquarters in Folsom, California

Colby Clegg CEO

With more than 100 years of experience in providing reliable, highquality products, Mitsubishi Electric is a recognized world leader in the production of industrial automation equipment. We support the needs of customers through the application of advanced technology in a broad product portfolio including PLCs, HMIs, VFDs, servo amplifiers and motors, control software, CNC, motion controllers, robots, and LVS, for the industrial and commercial sectors to facilitate smart manufacturing solutions for a more sustainable future.

Helping customers streamline operations, lower costs, and increase agility with advanced technology solutions. Our strength comes from the fact that we’re a single-source provider of game-changing technologies. We design and manufacture every core automation technology, including controllers, visualization systems, drives, motion systems and industrial robots.

“Our intelligent hardware, software, and service solutions help our customers transform operations, propel performance, and rapidly adapt to continuous change.”

Scott Summerville, President and CEO, Mitsubishi Electric Automation

Controllers: Our controller lineup is one of the most flexible in the industry. It is supported by one common programming software and an array of networking technologies to enable seamless connection to other products on the plant floor.

Drives and Motion: Our drive products range from stand-alone and PLCbased servo amplifiers and motion controllers providing tight single and multi-axis motion control, to a comprehensive line of VFDs engineered for high-performance and energy efficiency. In addition to performance, we focus on forward migration for easy upgrade to gain from new technology as products evolve.

Scott Summerville President and CEO, Mitsubishi Electric Automation

Industrial/Collaborative Robots: Our robotic line focuses on high-repeatability, high-speed applications with small to medium payloads, as well as specialized applications. Get seamless connectivity with our controllers to integrate and innovate more efficiently. Our robots are among the fastest and most accurate in their class.

SCADA Software: Our advanced visualization technology has high availability, centralized configuration and ability to connect to most industry standard communication protocols, making it easy to view and control factory operations and analyze data in new ways.

Time Sensitive Networking:

The integrated and open CC-Link IE TSN gigabit network offers time-sensitive networking (TSN) technology, enabling real-time data collection from the shop floor to IT systems.

Mitsubishi Electric Automation, Inc.

847-478-2100 us.mitsubishielectric.com/fa/en/

Mitsubishi Electric’s broad product portfolio is automating the world.

Powered by a global team of more than 1,000 diverse and passionate employees on every continent, Moxa stands committed to delivering innovative connectivity solutions that help its customers realize the vast potential of industrial automation and uncover business value at every step of their digital transformation journey.

At Moxa, an integral part of our DNA is engineering best-in-class, innovative network devices that enable industrial equipment to better connect, communicate, and collaborate across divergent systems and processes. Everyday our employees are motivated to push the boundaries to build the most reliable, scalable and secure network infrastructures possible that serve as the bedrock foundation for industrial operations. In doing so, we support enterprises in building resiliency today while enabling them to digitally transform their businesses for future growth.

With unmatched expertise in Industrial IoT systems, network security, and the integration of IT and OT networks, Moxa is accelerating progress for a broadening range of industries from traditional manufacturing, railways, and maritime systems to solar power, oil and gas, and intelligent transportation.

No matter which industrial sector we serve, we realize that the playing field has been permanently changed by digital transformation.

Industry 4.0 is no longer the exception to the rule — it is the rule for companies that must remain competitive in an increasingly global economy. Moxa supports businesses striving to be Industry 4.0 leaders by challenging their existing ways of working, by helping them adopt new network architectures, and by helping them leverage data and analytics to achieve operational excellence and enterprise agility.

No discussion of automation today is sufficient without addressing the threat of cyber-attacks. While IIoT devices have proven extremely helpful in collecting, storing, and sending data, many are not adequately designed to mitigate cybersecurity threats targeting critical infrastructure. Moxa is on the frontlines of battling malicious network attacks.

Chad Chesney President and General Manager, Moxa Americas

“At Moxa, an integral part of our DNA is engineering best-in-class, innovative network devices that enable industrial equipment to better connect, communicate, and collaborate across divergent systems and processes.”

At Moxa, our mission is to help drive the digital transformation of your business. Our goal is to improve its performance and topline growth by optimizing operations with the right technology investments. To learn more, visit www.moxa.com.

info@moxa.com • 1-888-MOXA-USA www.moxa.com

F|or nearly 50 years, control engineers, system integrators, and machine builders have looked to Opto 22 for innovative and affordable automation products.

Heard of OPC? We co-wrote the spec. Ethernet I/O? That was us. PACs? Us again.

We still embed these technologies in our latest industrial control and IIoT products. Our new groov® products run on standard Ethernet networks and offer multiple OPC UA server options.

But they also include the features you need today for digital transformation.

Opto 22’s groov EPIC® edge programmable industrial controllers and groov RIO® edge I/O are designed with integrated connectivity, control, and cybersecurity tools to help you connect automation, enterprise, and cloud data.

• Develop real-time control programs in a language you know: ladder logic, function block diagram, flowcharts, Python, C/C++, and more.

• Collect, process, and publish operational and energy data where it’s needed.

• Replace high-maintenance Windows PCs for HMI, OPC, and data processing with Linux-based industrial processors.

• Secure existing PLCs, traditional I/O, and standalone equipment, then integrate it with databases, business systems, and cloud services.

• Build dynamic operator HMIs for embedded or external touchscreens, mobile devices, and browsers.

• Securely access, monitor, and maintain systems at remote locations or customer sites.

Built on decades of field-proven experience worldwide, groov products offer lifetime guarantees on solidstate I/O, UL Hazardous Locations approval, ATEX compliance, and a wide -20 to 70 °C operating temperature range.

Why Opto? Opto 22 is a family-owned company founded and run by engineers for engineers.

• We design new products for the long term and provide upgrade paths, so your existing systems work with new ones.

• We keep building older products until we can no longer find required components, and even then we may re-engineer a product.

• We develop, manufacture, and support all our products in the U.S.A. Pre-sales engineering help and product support are free.

With nearly 50 years as a trusted automation manufacturer, we understand your projects and speak your protocols. Contact our engineers today.

Opto 22 factory and headquarters in Temecula, California

Mark Engman

Opto 22 President and CEO

Imagine a global, end-to-end partner for industry, dedicated to solving problems with innovation and expertise so customers can drive their business forward. Imagine that. RS can.

As an omnichannel solutions provider for designers, builders, and maintainers of industrial equipment and operations, RS (formerly Allied Electronics & Automation) aims to make amazing happen for a better world with an unrivaled choice of ground-breaking product and business solutions that keep core industrial companies up, running, and growing in the industrial automation, electronic, and electromechanical spaces.

company, RS Group, and make doing business with customers even more rewarding. They are on a journey to provide access to even more solutions, support, and expertise, with one goal: working together as an end-to-end partner for engineers, OEMs, and MROs in the Americas.

RS supports customers across the entire product life cycle, whether through innovation, engineering expertise, and technical support in the design phase, improving time to market and productivity in the build phase, or reducing purchasing costs in the maintenance phase. With tailored solutions that are essential for the successful operation of their businesses, customers rely on RS to deliver knowledge and help them save time and money along the way.

On February 6, 2023, Allied Electronics & Automation — a 95-year-old company with a rich history as a radio parts business turned industrial distribution giant — transitioned its brand to RS to increase partnerships with other companies under their parent

With more than 3.5 million products from more than 650 trusted suppliers in the Americas, RS carries more automation and control brand names than any other distributor in North America. It also offers a comprehensive suite of services and tools including the industry’s largest collection of 360° product images, an extensive range of 3D CAD models, more than 1.1 million up-to-date datasheets, and a highly experienced technical support team. In addition, RS publishes a series

“ [RS is] on a journey to provide access to even more solutions, support, and expertise, with one goal: working together as an end-to-end partner for engineers, OEMs, and MROs.”

of Expert Advice articles, interviews, and podcasts crafted to place critical industry knowledge and expertise at its customers’ fingertips and help them identify product and technology solutions as unique as their businesses.

As an employer, RS is committed to ensuring its organization is authentically and sustainably diverse to seek and embrace the very best talent. RS believes people are the center of its business and are vital to keeping the global organization moving forward. When it comes to company culture, the organization continuously strives to improve diversity, inclusivity, accessibility, and representation so that employees are empowered to bring their true self to work every day.

Tel: +1 (866) 433-5722 us.rs-online.com

Douglas Moody

RS President, Americas and Chief Services Officer, RS Group

As manufacturers continue to see their volume of rich, operational data grow exponentially with the introduction of new industrial and IoT sensors, the demand for scalable, reliable solutions that derive value from this data grows in parallel. Seeq SaaS solutions leverage cloud technologies to fulfill these demands, providing the scale it needs to support customers as they continue their paths toward digital transformation.

Seeq is a global leader in advanced analytics for the process manufacturing industries. Seeq helps companies address key initiatives in digital transformation, sustainability, and workforce empowerment with self-service, enterprise SaaS solutions that access and leverage their vast amounts of previously unused data. Oil and gas, pharmaceutical, specialty chemical, utility, renewable energy, and other vertical industries rely on Seeq to optimize business and production outcomes, including yield, margins, quality, and sustainability.

Dustin Johnson, Chief Technology Officer at Seeq, understands why horizontal scalability is driving modern software companies like Seeq to fully embrace cloud technologies. “To provide every user with a consistent, responsive, and easy-to-use experience, cloud technologies are required to scale performance and compute capacity to manage fluctuations in users and data volume capacity,” says Johnson. “At Seeq, our SaaS deployment model leverages cutting-edge clustering technologies, such as Kubernetes, and a scalable microservices architecture to support customers with employees and data sources located around the world. We make data from disparate sources securely accessible in one place and enable collaboration and knowledge-sharing across continents.”

With Seeq, you don’t have to wait until all your data is on the cloud to start gaining insights and value.”

Johnson continues, “The best part is that you can get started immediately. With many digital transformation initiatives, organizations plan to move data to the cloud to ensure ubiquitous data access as the first step, but this can be a long and complex process. With Seeq, you don’t have to wait until all your data is on the cloud to start gaining insights and value. Seeq enables immediate access to advanced analytics functionality wherever data is located, and when data is moved, users can continue to extract insights without interruption.”

Seeq cloud-native solutions can be deployed on Amazon Web Services, Inc. (AWS) or Microsoft Azure, ensuring engineers, operators, managers, and data scientists at locations around the world have global access to Seeq. “

Cli Ck or Scan QR code to request a DEMO.

Dustin Johnson Chief Technology Officer at Seeq

As a world leader in drive technology and a pioneer in drive-based automation, SEW-EURODRIVE has established a reputation for quickly solving the most difficult power transmission and motion control challenges. Since introducing the combined gearmotor in 1931, we have been bringing the best in drive technology to our customers worldwide.

SEW-EURODRIVE brings the best in drive and automation technology to our customers worldwide.

More than just gearmotors

SEW-EURODRIVE offers much more than just components. We offer the expertise and expanded line of control components and software to drive them. Our team of automation experts understand the latest technology and can solve even the most complex motion control challenges.

Being a single-source automation partner radically sets us apart from others. Our team of automation engineers provides the expertise, project planning, software, commissioning, and worldwide support for your most challenging motion control projects. They can serve as a valuable extension of your engineering team, reducing the stress and demanding workload. Our experts provide a solution of perfectly matched SEW components that have been designed to work together seamlessly.

PRODUCT INNOVATION

MOVI-C Automation Platform

In addition to engineering excellence, SEW-EURODRIVE is also known for innovative new products. Our MOVI-C® modular automation system is 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 the MOVI-C platform is that each of those components is designed to work together perfectly.

The MOVI-C platform utilizes the latest automation technologies –from AC motors and gear units to ultra-efficient permanent magnet servomotors, control electronics, and software. Machine builders will appreciate the seamless integration and prebuilt software modules tailored to the customer’s application.

MOVIGEAR® for decentralized drive installations

MOVIGEAR is the all-in-one mechatronic drive system that combines the gear unit, IE4 motor, and electronics in one compact unit. Recent updates include fully integrated Ethernet/IP communications and digital motor integration. Advanced single-cable technology carries power, feedback information, and control signals along a single hybrid cable between decentralized devices.

FLEXIBILITY

Our products are based on a unique system of modular components that can be assembled in literally millions of different configurations. So, every drive solution is custom built to our customer’s exact specifications. Our five regional assembly centers in the U.S. stock millions of dollars of our modular inventory for quick delivery of drive solutions and spare parts.

864-439-7537 www.seweurodrive.com

Skkynet is a global leader in real time middleware products and services that allow companies to securely acquire, monitor, control, visualize, network, and consolidate live process data in-plant or in the cloud. Skkynet software and services are being used in every industrial sector, with over 25,000 installations in 86 countries, including by the top 10 automation providers worldwide.

Skkynet’s unique DataHub® technology is redefining industrial loT. Our real-time middleware is secure by design with DMZ support, to provide unmatched tunnel/mirror capabilities for bridging on-premise systems and the cloud. It also offers unparalleled flexibility for MQTT connections, as well as remote connections to data historians.

Three new features have been added to DataHub’s powerful solution to meet the growing demand for secure integration of SCADA systems and data historians.

• MQTT smart broker handles up to 5,000 connections simultaneously, can connect MQTT devices from multiple vendors using JSON schemas, and includes support for Sparkplug B.

• Connectivity to real-time data historians like InfluxDB, OSIsoft PI, AVEVA Historian, AVEVA Insight, and Amazon Kinesis. Combining this feature with DataHub secure tunneling technology enables users to connect in-plant historical data to cloud applications, with store-and-forward support.

• Alarms and notifications can generate OPC A&E and OPC UA A&C alarms and notifications based on data flowing through the system, tunnel alarms across a network, and convert OPC A&E and A&C.

This core technology also powers Skkynet DataHub service in Microsoft Azure, providing secure connectivity on the cloud to hundreds of 3rd party tools available at the Microsoft Azure Marketplace. At the device level for IoT applications, Skkynet provides an Embedded Toolkit (ETK) for securely streaming embedded data.

Working in combination or separately, these tools provide full capabilities for any company looking for a hybrid and/or cloud implementation. Engineers and managers can securely network industrial data to and from multiple locations, consolidate information from remote plants and devices, share data for predictive maintenance, or use a real-time HMI to view data from around the globe. Secure by design, these solutions require no security hardware, no VPNs, and no changes to IT policies. Yet plant systems remain invisible to the internet.

Skkynet maintains OEM relationships with hardware and software providers and is a certified AVEVA technology partner. Skkynet customers include Microsoft, Siemens, AVEVA, Caterpillar, ABB, Gamesa, GE, Equinor, Goodyear, BASF, and the Bank of Canada.

The demand for secure data integration to the cloud is a critical requirement for most multinational companies.

Skkynet’s integrated products and services

Xavier Mesrobian

Vice President, Sales & Marketing

Skkynet Cloud Systems, Inc.

Innovations

Compact programmable logic controllers

The Allen-Bradley Micro850 and Micro870 2080-LxOE PLCs from Rockwell Automation are designed for large standalone machine control applications that require flexible communications and greater input/output (I/O) capabilities. These controllers support up to 304 I/O points with high performance I/O, interrupts, and pulse train output (PTO) motion plus embedded Ethernet port and Micro800 Expansion I/O modules. Other features include: Improved performance with increased I/O response and code execution time; increased protocol connectivity with new DNP3 and expanded DF1 communications support; enhanced protocol authentication in DNP3 with secure authentication version 5 (SAv5); optimized for connected components workbench software version 20.01 as the minimum requirement; recognition of controller options with catalog numbers containing E, for Ethernet connectivity, after the controller series. Rockwell Automation, www.rockwellautomation.com

Asset performance management platform

The asset performance management plaform i off-the-shelf, fully automated, end-to-end solution and is designed to help end users to unlock and process operational data for millions of machines. The platform remotely monitors industrial assets 24/7 to deliver real-time actionable knowledge required to stabilize operating performance, extend machine economic useful life and realize maximum return on these capital investments. It's offered as a cost-effective, single software-as-a-service (SaaS) subscription that provides everything a customer needs, including the sensors and solution with zero capital expenditure (capex). Features include: Smart sensors with direct to cloud connectivity; physics model asset library in cloud; self-supervised deep learning AI; predictive analytics diagnostic suite in cloud; and an open and extendable platform.

Shoreline, www.shorelineiot.com

Hazardous location linear position sensors

NewTek Hazardous Location Position Sensors monitor the structural integrity of liquefied natural gas (LNG) tanks, helping to meet Federal Energy Regulatory Commission (FERC) regulations for structural health monitoring. The sensors offer extremely accurate displacement measurement that is essential to monitoring the spacing between the tank containers, which is inaccessible by operators for years at a time. Features include: the ability to monitor the structural integrity of LNG tanks, which helps to meet Federal Energy Regulatory Commission (FERC) regulations for structural health monitoring; approved for use in Class 1, Zone 0, and Zone 2 locations. Newtek Sensor Solutions, www.newteksensors.com

Client computer-on-modules

The COM-HPC Client computer-on-modules are based on high-end processor variants of the 13th Gen Intel Core processors. The launch expands the already available portfolio of high-performance COMHPC modules with soldered processors to include the even more powerful socketed variants of this processor generation. The conga-HPC/cRLS Computer-on-Modules in COM-HPC Size C form factor (120x160mm) address application areas that require especially outstanding multi-core and multithread performance, large caches, and enormous memory capacities combined with high bandwidth and advanced I/O technology. Target markets are performance-hungry industrial, medical, and edge applications utilizing artificial intelligence (AI) and machine learning (ML), as well as all types of embedded and edge computing solutions with workload consolidation requirements for which Congatec also supports real-time hypervisor technologies. Congatec Inc., www.congatec.com

See more New Products for Engineers www.controleng.com/NPE

Control panel storage

DINStorage products are designed to store critical components such as spare fuses, tools and parts. The containers are designed to hold major brands like Littelfuse and Bussmann, as well as spare components, tools, write-tags, screws, communication adapters, and more. Designed to be mounted at the point of use with custom configurations, the storage solutions come in various capacities, sizes, and styles, including: Slotted-style fuse storage modules with access to spares; stacked-style store—a secure option for fuse storage in higher-vibration applications; and drawer-style storage, which includes clear drawers to store miscellaneous accessories and consumables. DINStorage, www.dinstorage.com

Remote data-collection module

The InvenSense SmartBug 2.0 is a smart remote data-collection module for IoT. This outof-the-box, one-size-fits-all solution offers remote monitoring, data collection, and specific IoT sensor application outputs via Bluetooth Low Energy and Wi-Fi. The sensor module also provides autonomous SD Card data logging for applications deriving value from large data volumes. The SmartBug offers a prototyping platform by enabling original equipment manufacturers (OEMs) to gain application insights, signatures, and environmental variations. Other features include: Supports ICM-45686-S IMU, the lowest power IMU from the BalancedGyro family; builds, deploys, and tests machine-learning models on ICM-456xy IMU; supports evaluation of TDK’s VibeSense360 solution for TWS; machine-learning models (Build, test and deploy); head tracking solution (TWS and XR devices); Air Mouse Solution (swipe gestures, position control); Lowest Power IM sensor (ICM-45686-S). TDK, www.tdk.com

Power supplies with EtherCAT interface

Beckhoff’s PS2000 power supply device series features a built-in EtherCAT interface. The PS2000 power supplies can remotely collect additional measurement and device diagnostics for comprehensive system monitoring, which can increase availability and reduce downtime. As a result, the feature-filled power supplies combine compact design and high performance with predictive maintenance functionality for the first time. The PS2000 variants combine high-performance power supply units from Beckhoff with the ultra-fast EtherCAT communication standard. This allows the control system to directly process extensive measurement data and internal device diagnostics information and establish remote access to power supplies. It also provides advanced monitoring features for the dc output (for system monitoring) or the ac input (for source monitoring).

Beckhoff, beckhoff.com

Vote for Product of the Year!

For the 2023 Control Engineering Product of the Year awards program (formerly known as Engineers' Choice Awards), 74 nominees cover 14 categories. Subscriber voting opened on Feb. 1 and closes March 14. See winners the next version of the Product of the Year eBook on Thursday, June 1. The ballot will be accessible via www.controleng.com/events-and-awards/product-of-the-year

INNOVATIONS

Environmental monitoring system

See more New Products for Engineers www.controleng.com/NPE

CloudEMS is a cloud-based environmental monitoring system (EMS) product leveraging modern web advances and IT technologies ensuring compliance and security now and into the future. CloudEMS provides an efficient and secure way to monitor environmental conditions in the laboratory, warehouse or production area. Users can collect data from sensors installed in the facility and store it in the cloud for later retrieval, analysis and reporting. With an intuitive user interface and real-time data, CloudEMS alerts users to environmental conditions that may affect product quality. Designed to help life sciences companies meet compliance requirements, CloudEMS ensures data is always securely accessible. Grantek, grantek.com

Fixed acoustic imager

The Fluke Process Instruments SV600 fixed acoustic imager enables users to detect, locate and visualize air and gas leaks or changes in sound signatures across their process and equipment in real-time before they become costly problems. By using an array of sophisticated sound sensors and powerful SoundMap technology, the SV600 translates the sounds that it hears into a visual representation so users can locate and quantify problem areas. The SV600 integrates with factory systems and can serve as an early warning system that can quickly detect changes across compressors, pumps, pipes, conveyors or across product inspection and quality control processes, and much more with user-defined alarms. Remote evaluation options, meanwhile, help to minimize operator intervention, even in hard-to-reach parts of the facility. Fluke Corp., www.fluke.com

PRODUCT MART FOR ENGINEERS

PLC Edge Gateway

Phoenix Contact’s PLCnext Edge Gateway software can collect data in the most demanding IIoT and edge computing environments. The downloadable app has an advanced industrial design and no code/low code programming to collect data from any device or sensor and send it directly to the cloud service. It is scalable for nearly any control system, from a single small machine to an entire manufacturing floor. PLCnext Edge Gateway requires no programming experience. The simple, webbased configuration uses checkboxes and simple prompts to configure connections. It is compatible with hardware in the PLCnext ecosystem, including the Phoenix Contact AXC F 1152/2152 controllers and Axioline I/O.

Phoenix Contact, www.phoenixcontact.com

Back to Basics

INDUSTRIAL PCS

Connecting legacy equipment

New and old equipment can work together seamlessly when industrial PCs (IPCs) come into the picture.

While all manufacturers would love to have a modern factory, this is unlikely to a reality for many – it is still commonplace to have aging equipment operating in a production line. According to Intoware’s independent survey of 1,030 UK-based industrial firms, 74% are still relying on legacy systems post-pandemic. This high percentile can be explained by the impact of the COVID-19 pandemic on businesses, with many feeling they cannot afford to invest in digitalizing production lines, especially small and medium-sized enterprises (SMEs).

While digitalizing factories can be challenging, it is easily achievable. Despite those who would say new and old technology cannot be blended, they can by retrofitting a few key components.

Rip and replace

in accelerometers and thermocouples to measure vibration, temperature, current and power consumption. Using IIoT devices to connect equipment to IPCs allows for the support of easy data acquisition that can help companies improve operational efficiency, and reduce energy consumption, projected costs and human errors in the factory.

‘ Retrofit IIoT connectivity and data acquisition into legacy equipment to cut energy consumption 17% and human errors by 70%.’

New machines are equipped to communicate with the Industrial Internet of Things (IIoT), so the quickest way of achieving a smart factory is to install a new system, the rip-and-replace approach. This has obvious benefits for systems communications, high efficiency and synchronization with emerging technologies.

For example, a 2019 case study by Felipe Orellana and Romina Torres proved that retrofitting legacy equipment with IIoT devices could successfully create an efficient smart factory. In the study, legacy equipment in a spare parts manufacturing factory was fitted with a variety of sensors connected to IPCs. This improved operational efficiency reduced energy consumption by 17%, reduced projected costs by 3% and cut human errors in the factory by 70%.

Disadvantages include initial cost, retraining and downtime required to replace equipment. Manufacturers who do not have the disposable capital for new equipment should seek to incorporate connectivity into legacy equipment, integrating new technologies and older machines by retrofitting. Legacy equipment could be costing companies due to the lack of data connection. The culture of uninformed decisionmaking persists despite the progress made in technology, with 26% of workers reported to have made decisions based on gut instinct during their careers, and 21% reporting doing this monthly. Manufacturers should seek to modernize factories for easier data acquisition. Retrofitting refers to adding IIoT connectivity capabilities to existing machines, so they can be monitored and controlled remotely. The easiest way to do this is by adding sensors for data acquisition or investing

This study shows companies can avoid the hefty cost of constantly updating equipment while still maintaining a competitive edge. The retrofitting process is a continuous improvement

that allows employees to become more familiar with digital technologies without throwing them into the deep end with new high-tech equipment, meaning they can see improvements to their tasks more clearly.

Retrofitting also is more environmentally friendly. Traditional manufacturing has a linear economy based on the makeuse-dispose model. Retrofitting is in line with the reuse-remake-recover model. ce

Adnan Khan is business development manager, Beckhoff UK. This originally appeared on Control Engineering Europe’s website.

Edited by Chris Vavra, web content manager, Control Engineering, CFE Media and Technology, cvavra@cfemedia.com.

See additional industrial PC stories at https:// www.controleng.com/ info-management/ industrial-pcs/ Onlineu controleng.com

KEYWORDS: digitization, industrial PC

LEARNING OBJECTIVES Understand challenges with mixing modern and legacy equipment at a manufacturing facility. Learn why a rip-andreplace method is not always the best solution and why augmenting legacy equipment through retrofitting can be more beneficial.

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StarterSET for machine automation

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INNOVATIONS

New Products for Engineers

Back to Basics

JANUARY/FEBRUARY 2023

5 FAST FACTS on exclusive Control Engineering research: How to apply controllers

Leveraging real-time data across the enterprise

TOP 10 Industrial Cybersecurity Pulse articles of 2022

System integration, edge computing tips for automation

For MQTT Smarter is Better -

Here’s why.

Bigger Challenges

Getting Smarter

More Useful

How next-generation automation will help in 2023

PLC module coordinates real-time data in coal shipping application

Changing conveyor routes and cargo train conditions

Improving operations with an in-chassis PLC module

Improving operations management and supply chain

Insightsu

PLC insights

Analysis: Ability to delay Microsoft DCOM hardening patch ends as of March 2023

Microsoft DCOM patch impact on OPC

Four solutions if not updated

Inertial measurement unit sensors lower risk for autonomous vehicles

TInsightsu

Safe-stop sensing system for autonomous vehicles

What is an IMU sensor, and how does it work?

IMU measurement;

IMU triple redundancy

A3 Forum: Optimism, caution on automation, economy

Beaulieu on manufacturing

Automation, growth

Automation opportunities

LOW-VOLTAGE ac motor market grows 21.2% in 2022

Automation mergers, acquisitions analysis: January 2023

Three 2023 insights

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in ControlEngineering for 2022 Hot topics

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Online controleng.com

Top 10 articles during 2022

Hot topics, July-December, covers

Top 3 covers of 2022

Content Specialists/Editorial

Contributing Content Specialists

Making machine control open, secure

Fixing the supply chain

Matching labor skillsets to controllers

Automation to withstand cyberattacks

Match the pace of automation

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Insightsu

Machine control

OEM and end user cooperation

Integrating more capable controllers

Taking control of your control system

Reasons to modernize the control system

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Insightsu

Control systems

A better way to modernize controls

Modern controls, less downtime

Shift costs to ease budget strain

Eliminate control system roadblocks

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PLC programming: Do this, not that

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PLC programming: Eight tips to follow; five practices to avoid

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Ethernet reliability in the age of IIoT, digital transformation

Ethernet can enable better IT/OT coordination and improve communications, reliability.

Five benefits to advanced Ethernet use

Eight frequently-neglected VFD parameters to optimize