Level sensors monitor the level of liquids, pellets, powders, and other similar products in tanks and process systems.
• Ultrasonic level sensors
• Float, capacitance, and vibration level switches
• Rotating paddle level switches
• Guided wave radar level sensors
• Differential pressure level transmitters
NEW! Endress+Hauser Capacitance Level Switches
Starting at $221.00 (FTI26-CA4MWDG)
Endress+Hauser capacitance level switches are contact sensors that provide point-level detection of powders, fine-grained bulk solids, or water-based conductive liquids. Many models have hazardous location ratings or are FDA-compliant for food and beverage industry applications when installed with appropriate hygienic fittings.
• DC PNP switches and IO-Link communication output options
• Select models are marked with the 3-A symbol for food and beverage industry hygienic applications
Temperature sensors provide accurate and reliable feedback for temperature control and monitoring applications.
Flow Sensors
Starting at $73.00 (FG1W-100PP-28)
Endress+Hauser submersible level sensors provide continuous liquid level measurement by sensing the hydrostatic pressure produced by the height of liquid above the sensor, providing a 4-20 mA output signal compatible with PLCs, panel meters, data loggers, and other electronic equipment.
• Up to 2 bar (66.9 ftWC) sensing range
• Rugged 316 stainless steel construction
• NSF Certified models for drinking water applications
• Models with FM hazardous location approvals for intrinsically safe applications
• Thermocouples, RTDs, and thermowells
• Magnetic-inductive flow meters
• Thermal and vortex flow sensors
• Variable area mechanical flow meters
Pressure Sensors
Starting at $87.00 (QPSL-AP-42)
• Mechatronic flow switches and transmitters
Flow measurement devices monitor liquid media and provide reliable flow indication, detection, or measurement.
• Pressure switches and transmitters
• Digital pressure switches/transmitters
• Differential pressure transmitters
• Winters pressure accessories: siphons, snubbers, and isolation needle valves
Starting at $240.00 (SCU-2502)
Pressure sensors measure pressure at a specific point in the process and transmit the measured value or trip point to a control device.
NEW! ProSense Frequency Signal Conditioners
ProSense frequency signal conditioners are extremely versatile, affordable, and will convert, transmit, scale, and isolate input signals from a wide variety of process sensors and controller I/O.
• SCU-2501 universal frequency transmitter with analog and relay outputs
• SCU-2502 universal frequency transmitter with (2) relay outputs
• SCU-2503 universal frequency transmitter with analog and frequency outputs converters
• Various types of metallic and non-metallic constructions
• And much more...
NEW! More Murrplastik Cable Entry System Options...
Murrplastik cable entry systems allow installation of non-terminated or pre-made/terminated cables through an enclosure or other bulkhead surface.
Our new additions include:
• The KDP/R series: A round one-piece frame available in two different frame sizes that can hold up to 46 non-terminated cables in a single frame.
• FDA compliant cable entry systems ideal for food, beverage, pharmaceutical, and any industry requiring sanitary components.
– KDL/H-VA-FDA series: Stainless-steel split frames, available in three sizes that can hold up to 12 pre-made or terminated cables.
– KDP series FDA Cablequick® system: A one-piece stainless-steel frame that can hold up to 56 non-terminated cables.
KDP Series
KDP/R Series Series
Series
When you need A REAL SCADA HISTORIAN
INSIGHTS
MARKET UPDATE
NEWS
17 | Applications for collaborative robots; Q1 robot orders compared to ’22; May mergers
18 | Digital transformation; RSA Conference 2023: How to secure OT systems; Digital thread and manufacturing productivity; Additive manufacturing digitalization, motion control; ONLINE: Eight more headlines you may have missed.
ANSWERS
25 | The best automation, control and instrumentation products, as selected by engineers 26 | How to use a lifecycle digitial twin to streamline carbon-capture
INNOVATIONS
60 | New Products for Engineers – See more products in every issue.
Electro-hydraulic actuators, metering gear pump, plug-in motor controller, spring-loaded position sensors, capacitance level switches, cabinet coolers, industrial analytics software, power converters, input rack PDU, multiport serial board, temperature transmitter, photoelectric sensors
See more products online. www.controleng.com/products
63 | Back to Basics: 5 edge technology trends, insights
NEWSLETTERS
ONLINE
Control Systems
• Career and Salary Survey insights, Three HMI and SCADA development tools, motion control, virtualization, distributed control
IIoT Sensing, Connectivity and Analytics
• Scaling Industry 4.0 transformation, Most-viewed IIoT articles
• With more on digitalization, automation, sustainability, productivity; Modern intelligent device management with IT/OT data-driven operations; and how sustainability can drive digitalization
Edge Computing
• Manufacturing transformation: Edge tech and digital trends shaping the industrial sector
System Integrator of the Year; Top projects, advice; Outlook, trends, training; System Integrator Giants, research and more. www.controleng.com/GSIR
u Control Engineering eBook series, now available: Summer Editions
Digital Transformation
What does digital transformation mean for manufacturers and what effect will it have for the present and future? See examples digital transformations taking hold in manufacturing. Featured articles include MQTT’s benefits for digital transformation, digital transformation’s importance for manufacturers and others in this 68-page eBook.
AppliedAutomation
This eBook demonstrates how automation, instrumentation and control techniques are applied to increase capacity, enhance design and production, improve efficiency, increase profitability and meet regulatory requirements. Featured articles include logistics, robotics advances at the heart of improving automation and understanding the basics of automation validation.
See the eBooks above and other topics at: www.controleng.com/ebooks
u Control Engineering digital edition
The tablet and digital editions provide links to other related, useful resources. Click on headlines to see online version with more text and often more images and graphics.
www.controleng.com/ magazine
Online Highlights
Systems integrators are not 'one size fits all'
u WORKING WITH systems integrators (SI), it’s inevitable that at some point someone will say, “We’re not a typical SI.” And in many ways, it’s true. SIs come in all shapes and sizes.
Machine builders and automation equipment suppliers often offer integration services. IT consultants can be a kind of SI. Engineering, construction and procurement (EPCs) providers integrate the infrastructure and operations spaces. Even large B2B electronics distributors are introducing high-margin service offerings for things like lighting and motors and drives.
Automate 2023: Sensor insights
u INFORMATION is a major asset for any company trying to maintain supply chains and improve operations. The data gathered from machines, sensors, modules and more are sent to the cloud or a secure hub and analyzed into something tangible for operators to act on. During Automate 2023 in Detroit, some companies emphasized sensor technology as a way to glean valuable insights.
SIs focused on process control or factory automation can offer proprietary hardware devices or software apps that support the connectivity central to today’s operational endeavors. Besides having a business or technology focus, SIs also can be classified by industries and region served.
Systems integrators of all kinds were in the mix at the recent CSIA Executive Conference 2023 May 15 to 19 in New Orleans.
Labor shortages can create demand for automation solutions. By means of systems integrators, the resources for applying automation solutions are made more widely available. Positioning technology know-how where it can have most impact, systems integrators work with industrial enterprises to design, test, connect, implement and upgrade automated systems to optimize productivity and ensure reliability, save energy or augment safety. By combining sophisticated emerging technologies with practical, hands-on experience, systems integrators provide productivity improvements powered by the convergence of operations and information technologies.
With this article online (click the digital edition headline), learn more about system integration in food and beverage industries, automation architectures, cloud-based help for automation, PID and control optimization. ce
Kevin Parker is senior contributing editor, CFE Media and Technology.
Motor control maintenance and troubleshooting best practices, advice
u ELECTRIC MOTORS are used to drive actuators and machines in industry and there are ways to keep them operating efficiently.
EXAMPLE of a three-wire “hold-in’ circuit.
Courtesy: Automation LLC
This article covers starters and overloads, soft starters and variable frequency drive control and has 10 figures (photos and diagrams) to help. Click the headline in the digital edition to read the article.
This has been edited from the “Maintenance and Troubleshooting in Industrial Automation” book by Frank Lamb, the founder and owner of Automation Consulting LLC and a member of the Control Engineering editorial advisory board. ce
Kevin Ouellette, product marketing specialist at Cognex Corp., described the trevista dome from SAC, which is connected to Cognex software, as a way to inspect a surface. The trevista dome is designed to see more because it represents the surface shape of the inspection objects plastically and makes defects in the micrometer range visible.
SEE MORE IMAGES and a video clip with a Cognex camera scanning and learning on a Universal Robots collaborative robot, with this article online. In the digital edition, click the headline. Courtesy: Control Engineering
“It takes images one quadrant at a time and through this process defects are highlighted,” he said. It combines 2D and 3D images to provide depth. “We can resolve a 3D image and measure the severity of a flaw. This lets the user determine whether to reject a part or not and it reduces overkill.”
While the marriage of the two technologies was being promoted for electric vehicle (EV) battery production, Ouellette said it can certainly be applied to other applications such as body panel inspections on a car or an aircraft’s wings. While the Trevista is designed for larger applications, Cognex also has smaller cameras designed to find defects and transmit the information to the user for appropriate responses. Related algorithms learn to operate better in the future. Eduardo Arcis, senior applied engineer at Cognex, described the In-Sight 3800 as being able to process much faster with fewer samples and it uses edge learning. The In-Sight D900 vision system is designed to provide complex applications that are too difficult to deploy with traditional, rule-based machine vision while providing results not possible with human inspection. Arcis explains more in a video demonstration. ce
Chris Vavra, web content manager, CFE Media and Technology, cvavra@cfemedia.com.
JOSE RIVERA is CEO of the Control System Integrators Association. Courtesy: CSIA
DataHub
Cogent DataHub allows you to seamlessly integrate your live processes using standard protocols like OPC, MQTT and Modbus, and connect to SCADA systems, data lakes and historians securely and in real-time. Solve your IoT connectivity issues. Secure your OT to IT data communications. Reduce your cybersecurity risk profile. Share your data with any application, partner or customer. All in one solution now available at Microsoft Azure Marketplace.
Next-generation development tools help equipment intelligence
Manufacturing industries need to develop new concepts of automation core component products and software development tools for future digitization and intelligence.
With the rapid development and deepening of digitalization and intelligence of industrial equipment, new technical requirements are put forward for core automation products and software, including programmable logic controllers (PLCs), human-machine interface (HMI), supervisory control and data acquisition (SCADA) and other automation and controls.
The contradiction between the existing relatively old development tools and the new technical requirements is becoming more obvious. Ma Xuetong, the general manager of Shanghai Flexem Technology Co. Ltd. offers advice about how to get past technical bottlenecks to accelerate equipment intelligence.
New challenges for older automation
Due to the development of automation before computer technology and the internet, many development tools for core components of traditional automation are “inherently inadequate” and are now difficult to adapt to the needs of the times. To meet these challenges, in 2019, Flexem launched the research and development of FlexMI series products. The latest FlexMI series of products and development tools were launched in early 2023. The products enable modern automation concepts such as modeling and data decoupling, building web-based user interfaces (UIs) and providing high-level programming language support.
FlexMI series products cover the manufacturing execution system and enterprise resources planning (MES/ERP) software capabilities with products including PLC controllers, HMI, edge-computing gateways, SCADA software, covering the control layer, display layer, access layer, monitoring layer and management layer. FlexMI adopts a unified develop-
products
software
ment tool FStudio Unified software (FSU), covering the integrated development of PLC, HMI, edge gateway and SCADA software. The integrated development environment improves development efficiency.
Xuetong said, “Innovation is the DNA of Flexem. Embrace change, be brave to try and dare to be the first in the world. New technology brings new challenges and new opportunities at the same time. Standing at the forefront of technological innovation and offering industrial customers new productivity tools with new technologies, we are working to advance equipment intelligence, step by step.” ce
Stone Shi is executive editor-in-chief, Control Engineering China. Edited by Mark T. Hoske, content manager, Control Engineering, CFE Media and Technology, mhoske@cfemedia.com.
controleng.com
KEYWORDS: Digital transformation, modern automation design ONLINE www.controleng.com/ international
With this article online (click the digital edition headline), see more on these topics: New automation tools Adding design sense to HMIs with a style template Get ready for AI for industrial automation
Stone Shi, Control Engineering China
Ma Xuetong, general manager of Shanghai Flexem Technology Co. Ltd., said new technology brings new challenges and new opportunities at the same time. Flexem Technology’s FlexMI series of
adopts a unified development tool FStudio Unified
(FSU), covering the integrated development of PLC, HMI, edge gateway and SCADA software. Courtesy: Control Engineering China
RIDING THE WAVE:
Adaptive pump captures ocean energy
Capturing energy from ocean waves converts the motion of the ocean into electrical energy using a new pump mechanism called the dynamic adaptive piston pump.
Anyone who has been on a windy beach or on the stormy seas has experienced the power of the ocean. That power has been a largely untapped energy resource—until now. New pump mechanisms will soon allow wave power to be converted into electricity, offering a new clean energy option.
How does a wave energy converter work?
Harnessing wave energy is made possible by a new type of pump mechanism dubbed the dynamic adaptive piston pump (DAPP); see graphic.
The DAPP system consists of an upper cylinder and a larger lower cylinder stacked vertically with a smaller movable cylinder between them. When the movable cylinder shifts downwards, the pressure of the fluid inside forces the outflow valve at the bottom of the lower cylinder to open, and the contents are expelled. With the lower cylinder empty, the pressure from the liquid beneath the unit pushes the outflow valve closed. Then, with the movable cylinder at its lowest position, more fluid flows into the upper cylinder. The pressure of the incoming fluid forces the valve at the bottom of the movable cylinder to open. The internal redistribution of the contents causes the movable cylinder to automatically move back to its upper position and creates pressure to close the valve at the bottom of the movable cylinder.
The pump can be installed in an ocean buoy that takes wave power and turns it into electricity. The device would need to be anchored to the ocean floor and have a pre-tension system to pull the buoy downwards. Ideally, the buoy would be around 18 meters tall and 9 m diameter. Wave swells carry the buoy upwards. The buoy is forced downwards by stored pressure inside a pneumatic cylinder. The buoy’s up and down motions create energy via a mechanical drivetrain, with gears that rotate relative to bobbing.
The key components enabling wave energy harvesting include two medium-voltage motors (one to
drive the test rig and a second to handle energy storage), and as medium-voltage switchgears in the buoy that deal with the generated energy and powers the motors.
Although harnessing wave energy may sound futuristic, half-scale prototype has already had one successful test off the coast of Scotland. The next phase of testing is currently underway, which involves building a full-scale rig. The plan for later this year is to build a full-scale fleet of buoys and start generating wave energy in an electric power grid.
Advantages of wave power
Ocean waves have characteristics that make them ideal for power generation: reliable forecasts of high seas, predictable currents and dependable waves. This energy can be combined with wind and solar to yield a stable mix of clean power. Fossil fuels deliver baseload power daily; wave power could also.
It’s essential to diversify clean energy sources. Although solar panels and wind turbines are making great gains, the International Energy Agency (IEA) reveals that more than 80% of the world’s energy is still derived from fossil fuels, a level that has been constant for decades. According to the NRDC, fossil fuels are responsible for land degradation, water and air pollution and other environmental harm.
Wave energy is a global solution. Conditions suitable for wave power generation can be found around the world with little or no correlation to wind or solar conditions. Ocean energy eliminates the need for large structures on land. Wave power creates stable electricity that is predicted to be among cheaper longrun options. ce
Randall Scasny is senior community content specialist, Newark. Edited by David Miller, Content Manager, Control Engineering, CFE Media and Technology, dmiller@cfemedia.com.
THE DYNAMIC adaptive piston pump (DAPP) system consists of an upper cylinder and a larger lower cylinder stacked vertically with a smaller movable cylinder in between them. Courtesy: Newark
KEYWORDS: industrial pump design, sustainability
LEARNING OBJECTIVES
Learn how a dynamic adaptive piston pump converts ocean waves into electricity.
Learn why wave-generated energy offers advantages over other forms of clean energy production.
How can automation help sustainability and profits? Online controleng.com
Are you using the available $1 billion to patch critical infrastructure vulnerabilities?
Critical infrastructure organizations need to use the $1 billion in Department of Homeland Security funding to bolster cybersecurity for critical infrastructure vulnerabilities.
Understand which industries are getting $1 billion in cybersecurity help and why critical infrastructures are at risk for cybersecurity threats. Review vulnerability management best practices and how adapting more robust cybersecurity outweighs cyberattack costs.
CONSIDER THIS Are you investing to decrease cybersecurity risks or risking losing your investments?
ONLINE
With this article online, see how IT and OT cooperation can help cybersecurity.
Wayne Dorris discusses ransomware threats with Industrial Cybersecurity Pulse, a Control Engineering sister publication.
The Department of Homeland Security announced distribution of $1 billion to fund critical infrastructure cybersecurity efforts in September 2022. This necessary movement towards cybersecurity goes with more industries undergoing digital transformation. It is not as simple as throwing money at the problem. Challenges in critical infrastructure have led to slow implementation of cybersecurity solutions and best practices.
Which industries get help?
DHS defines critical infrastructure in 16 sectors: chemical; commercial facilities; communications; critical manufacturing (primary metals manufacturing, machinery manufacturing, electrical equipment, appliance and component manufacturing; dams; defense industrial base; emergency services; energy; financial services; food and agriculture; government facilities; healthcare and public health; information technology; nuclear reactors, materials, and waste; transportation systems; and water and wastewater).
Vulnerability management
With how rapidly digital transformation has taken hold, many organizations have been slow to adopt good vulnerability management practices. Cybercriminals move much more quickly, and they have been happy to exploit the new vulnerabilities. The SolarWinds attack was a major wake-up call for many in critical infrastructure, and the ability of an attacker to exploit an unseen vulnerability and cause massive disarray has led to new industry regulations mandating increased transparency. Any entity doing business with the government or receiving government funds is required to provide transparency in its software.
Today, responsible developers or device manufacturers are expected to provide a software bill of materials (SBOM), which will explain what is in the
software itself and how it’s used. The theory behind this degree of transparency is to allow for vulnerability scanners to do their jobs. A vulnerability scanner cannot detect a vulnerability it doesn’t even know to look for. For this same reason, open-source components are becoming more popular in the security industry. Open-source code has no secrets; any vulnerabilities can be identified and patched.
The government is stepping in to fund cybersecurity improvements, but this comes with the expectation that certain requirements are being met. Department of Homeland Security (DHS) teams conduct assessments for organizations in critical infrastructure, which means most should have a fairly clear idea of priorities. The Cybersecurity and Infrastructure Security Agency (CISA) also publishes a list of guidelines, including recommendations for where critical infrastructure organizations can get the most return on investments. In the past, it was up to organizations to figure out how to meet those recommendations. The government’s new willingness to help fund cybersecurity initiatives has put more effective solutions within reach for organizations that need them.
Robust cybersecurity vs attach costs
With cybersecurity, it is only a question of when, not if, a cybercriminal will get an organization. Adaptation is not painless, but it outweighs the cost of a devastating cyberattack. In the past, the government would provide assessments. With this funding distribution, the means are provided. Critical infrastructure organizations no longer have an excuse; they need invest this new funding into actionable steps to address vulnerabilities. ce
Wayne Dorris, CISSP, is program manager of cybersecurity, Axis Communications. Edited by Mark T. Hoske, content manager, Control Engineering, CFE Media and Technology, mhoske@cfemedia.com.
Cybersecurity, industrial Ethernet
Manufacturing facility devices need cybersecurity with internet connections.
Cybersecurity will become the big topic in industrial communication technologies as it has been in IT for many years now: the connectivity required by the Internet of Things (IoT) and Industrie 4.0 concepts means the controls engineer also will have to deal with the topic. When and to what extent depends primarily on two decisions: what the network architecture looks like and which network technology is used.
The importance of architecture models
For the architecture, a hierarchical model has worked well up to now. The real-time control network — the control-level fieldbus to which the input/ outputs (I/Os) and drives are connected — is separated by the controller from the higher-level communication systems and the plant network. The controller provides and conditions the process data the higher-level systems require and regulates access to the lower-level devices, such as the I/O nodes.
The controller acts as a cybersecurity firewall for the underlying network and transforms raw data from the I/O level into meaningful information. Transporting data directly from the sensor to the cloud only makes sense in some select cases. For example, the user cannot know without further information if a motor temperature of 85C is OK or too hot. In many cases, the motor knows this because it depends on the application and the current situation. A controller, on the other hand, can tell the operator’s cloud service in addition and if the current motor temperature is acceptable.
For those cases where the provision of raw data is desired, the user should be able to decide to allow that or not. This is much easier to do in the controller than on each sensor or device.
For some, the hierarchical architecture is outdated. They demand complete access with a one network from “bottom to top.” This is also the justification for demanding the same network technology below the controller as above — there should be no more “below” and “above.” While tempting, this approach has many problems for responsibility and liability, independent performance of the con-
trol network, address duplication and costs. Cybersecurity risk increases when I/O nodes, networked sensors and drives are visible and accessible in the plant network and beyond. Users do not even have to assume deliberate attacks: Even an accidental change of parameters on the wrong device would have far-reaching consequences.
No switch-based industrial Ethernet
In this brave new world, all devices must have cybersecurity protections. That means certificates on every I/O device. The certificates expire after a period of time and must be updated. Security requires additional computing power and memory on the devices, and this leads to increased costs. Meeting security requirements with this architecture means controls engineers must build cybersecurity know-how.
The choice of network technology plays a key role. With switch-based industrial Ethernet solutions, each device must be cyber-protected, especially if the technologies are fully or partially based on the internet protocol (IP). EtherCAT, on the other hand, is neither switch-based nor does it rely on IP: The EtherCAT protocol is embedded in the Ethernet frame.
Since almost all cyberattacks require the IP for routing, with EtherCAT the cyberattacks go nowhere.
EtherCAT chips filter out non-EtherCAT frames by hardware, and, by principle, EtherCAT devices cannot be persuaded to falsify data not intended for them, even by compromised firmware. EtherCAT ports that are not used can be switched off in hardware.
EtherCAT is well protected, and no further cybersecurity measures are required beyond what is required to harden the controller to industry cybersecurity standards. No knowledge of certificates or cybersecurity is required to operate the EtherCAT industrial Ethernet fieldbus. With EtherCAT, cybersecurity concerns are covered. ce
Martin Rostan is executive director of the EtherCAT Technology Group, a CFE Media and Technology content partner. Edited by Chris Vavra, web content manager, Control Engineering, CFE Media and Technology, cvavra@cfemedia.com.
‘ EtherCAT is not switch-based and doesn't rely on IP. Since almost
all
cyberattacks require the IP for routing, with EtherCAT the cyberattacks go nowhere.’
How is Ethernet use affecting your cybersecurity? Online controleng.com u
KEYWORDS: Ethernet, cybersecurity
LEARNING OBJECTIVES
Learn about the importance of industrial network structures and why they matter for manufacturing facilities.
Learn how EtherCAT can help manufacturers improve networking hierarchy and cybersecurity posture.
ONLINE
See more on Ethernet at https://www.controleng. com/industrial-networking/ ethernet/
CONSIDER THIS
Justify modernization
See 6 control system update justifications.
Justifying a control system modernization project is a task that many plant support personnel or corporate engineers may be required to do. The reasons for this have changed over time. While some drivers never go away, others have evolved, and still more are new.
1. When automation support ends
u
Online
controleng.com
See more details for each of the six points with this article online. Reading the digital edition? Click on the headline for the longer online version.
The predominant driver for control system modernizations has always been hardware and software obsolescence and end of lifecycle support. This is sometimes referred to as “depreciation.” As suppliers upgrade their products and introduce new lines, previous offerings are phased out. As a result, manufacturer support becomes more expensive and may even cease altogether.
2. Cybersecurity risks
UPDATING a control system requires justification. Are you including these six reasons in your calculations? Information courtesy: Applied Control Engineering Inc.
The core concerns surrounding control system cybersecurity have been around for decades. The 2010 publicization of Stuxnet coupled with the release of NIST’s Cybersecurity Framework several years later has increased interest in the field. Many new cybersecurity technologies are available for new control systems. Previously, ICS cyber controls may have been limited to using a second NIC card for network isolation, but current security programs are likely to include firewalls, access control, anti-virus (or other EDR), automated backup and intrusion detection. These are more cost effective when paired with control system modernization.
3. Embedding retiree knowledge
Many experienced manufacturing workers have already retired. COVID-19 and the Great Resignation have accelerated their exodus. Companies that didn’t capture institutional knowledge or implement new control systems before their departure are now at a major disadvantage. Other workforce concerns include the tight labor market and labor shortages. Shortening the training time through
use of a digital twin is one solution. Another is the implementation of human-machine interfaces (HMIs) that support good design practices and easier troubleshooting.
4. Control system safety
Other justifications exist for control system modernization. For example, electrical safety and arc flash protection has come to the forefront in recent years. Safety is often the leading value for manufacturers and older control panel designs; extensive use of 120VAC I/O needs to be reviewed. When integrating AC voltages for controls, a new enclosure can segregate the dangerous voltages from low voltage equipment. In these cases, an electrical safety budget may be tapped to help fund a modernization project.
5. Continuous improvement
Another new driver is continuous improvement methodologies that aim to squeeze more value out of limited plant resources. Gathering data and sharing it with a manufacturing execution system (MES) that is performing overall equipment effectiveness (OEE) calculations is an example of this. Big data initiatives, predictive maintenance and analytics also fall in this category. This entails getting contextualized information to the right person in the right place.
6. Help sustainability efforts
With sustainability goals prevalent among manufacturing companies, operators should evaluate if their control system can support those goals. If not, a control system modernization project may need to be part of the corporate sustainability push. Having a control system that allows for the optimization of equipment usage is one way. That optimization is an easy win for sustainability. Many plants are replacing fixed-speed motor starters with VFDs. These can be more energy efficient, and there is a measurable payback. Having a control system that allows for process changes to reduce waste and off-spec products falls under sustainability to help companies reduce waste. ce
Ian Burns is president, Applied Control Engineering Inc. Applied Control Engineering is a Control Engineering content partner. Edited by David Miller, content manager, Control Engineering, CFE Media and Technology, dmiller@cfemedia.com.
How to simplify PLC, control device management with Git version control, auto-backup
Webcast on PLC and control device programming explains Git version control and automated-backup capabilities help simplifying programmable logic controller (PLC) and control device management.
Some industrial automation professionals are harnessing the power of modern DevOps solutions (workflow practices adopted for software development and IT operations) that are the standard for traditional software development. Unlocking Git version control for PLCs and control devices means all projects and code changes are tracked and securely stored so the latest version of code is easily identified. Information below previews some of the information in the webcast, “Simplifying PLC and Control Device Management with Git Version Control and Auto-Backup.”
Webcast presenters in the webcast, 1 p.m. on April 25 and archived for a year thereafter, are Matt Lee, co-founder and vice president of business development, and Vaughn Varma, technical marketing manager, both with Copia Automation. A certificate of completion and download of the presentation are available for attending, along with opportunity to ask questions, for registrants listening live on April 25. They cite a Forrester report on Git that says its use reduces onboarding and training by 40%, while 85% of survey respondents say Git helps them to write and deploy better code. Also, developer satisfaction increased.
Improve control workflow capabilities
Lee and Varma explained how non-text-based languages like ladder logic, structured text (ST) and function block (FB) diagram can be visualized with changes highlighted in a browser, which gives reviewers information more quickly. Such tools can
PRESENTERS
Presenters of an April 25 Control Engineering webcast (archived for a year), “Simplifying PLC and Control Device Management with Git Version Control and Auto-Backup,” are Matt Lee (left), Copia Automation co-founder and vice president of business development, and Vaughn Varma, technical marketing manager, Copia Automation. Courtesy: Copia Automation
be used for monitoring and managing machinery in production, ensuring the project on record aligns with the machine state. The webcast also provides an introduction to Git version control and describes benefits for industrial automation. Software functions like these can work alongside the current automation or operations environment to streamline workflows, increasing productivity, efficiency and quality.
Versioning, backup benefits
Lee and Varma explain eight common issues Git can resolve for those working with automation device programming.
1. Lose code or use a backup that was too old
2. Search endlessly for code to reuse
3. Maintain multiple versions of a file
4. Have difficulty seeing the difference between versions
5. Cannot quickly share code
6. Work off of a version that was outdated
7. Don’t know who changed what, when, and why
8. Have trouble scaling teams.
By having multiple engineers work on a project more efficiently, talent can be used where needed the most while working on the same code base. ce
Edited by Mark T. Hoske, content manager, Control Engineering, CFE Media, mhoske@cfemedia.com.
How to build a better HMI with collaborative, modern, cloud technology
Rockwell Automation, with its 2020 acquisition of ASEM, said collaborative HMI software-as-a-service (SaaS) to enable workflows, track changes and versioning. Learn more in a May 11 webcast.
Building and maintaining human-machine interface (HMI) systems can provide collaborate efficiencies for automation and operations teams by using software-as-aservice (SaaS) to enable workflows, track changes and versioning. A new visualization platform accelerates value delivery with modern technologies, innovative designs and scalable deployment options. Rockwell Automation experts explain how the Rockwell Automation 2020 acquisition of ASEM, a provider of HMIs and industrial PCs (IPCs), is helping industrial automation users to:
PRESENTERS
Steve Briant, visualization platform lead, Rockwell Automation, and Mark Hobbs, software senior product manager, Rockwell Automation, explain how new tools enable automation users, original equipment manufacturers (OEMs) and system integrators to “Build a better HMI with collaborative, modern, cloud technology” in a May 11 Control Engineering webcast (archived for a year). Courtesy: Rockwell Automation, Control Engineering webcasts
• Learn how to harness the cloud and become more agile through collaborative engineering.
• Understand how to create an HMI application and deploy to any device.
• Learn how to style HMI graphics for a global audience.
• Explore how to build HMI designs from the ground up integrating OPC UA and extensibility that supports Industry 4.0.
Steve Briant, visualization platform lead, Rockwell Automation, and Mark Hobbs, software senior product manager, (photos) Rockwell Automation, said new tools enable automation users, original equipment manufacturers (OEMs) and system integrators to “Build a better HMI with collaborative, modern, cloud technology.” The May 11 webcast; it is archived for a year
and offers a certificate of completion. It covers more advantages by offering product information, an explanation of design and operations collaboration, modern graphics design and open extensibility.
Product information, specifications
FactoryTalk Optix (FT Optix), a product introduction in the Rockwell Automation FactoryTalk line, resulted from the Rockwell Automation and ASEM collaboration on a new HMI offering in the visualization portfolio. Briant and Hobbs described the software for HMI, industrial Internet of Things (IIoT) and smart manufacturing applications as a “new open, scalable visualization platform with options,” fitting into the FactoryTalk Design Hub Ecosystem by Rockwell Automation. They described the automation design SaaS journey in three steps:
1. Make data accessible by moving it to the cloud.
2. Rehost familiar applications on the cloud to more easily collaborate.
3. Create new, native cloud-based applications.
Using HMI graphic terminals with automation design software provides a ready-to-run solution, Briant and Hobbs said, with modern graphics capabilities and open extensibility and connectivity. ce
Edited by Mark T. Hoske, content manager, Control Engineering, CFE Media and Technology, and webcast moderator, mhoske@cfemedia.com.
Online controleng.com u
KEYWORDS: Human-machine interface, HMI design
LEARNING OBJECTIVES
Understand product information, specifications for FactoryTalk Optix, a new open, collaborative, extensible HMI. Learn how selection, design, use and maintenance of HMIs can be easier with less risk.
CONSIDER THIS
Does your human-machine interface system enable open and scalable connectivity, collaboration, easier implementation? ONLINE https://www.controleng.com/webcasts/build-a-better-hmiwith-collaborative-modern-cloud-technology
Application scenarios for collaborative robot market
According to updated research by market intelligence firm Interact Analysis, the collaborative robot (cobot) market will enjoy modest growth out to 2032, with annual growth rates sitting at around 20%. “Collaboration” between humans and robots is now widely accepted so robot manufacturers suggest that the key to future success will be their ability to scale up production and develop new application scenarios. The logistics industry will also play an important role in this growth trajectory.
As with all industries, the current economic landscape and the Ukraine-Russia war have had an impact on the collaborative robot market. Out to 2027, shipments of collaborative robots in EMEA will decrease from 19.5 to 15.9%, with a compound annual growth rate (CAGR) of 22.4%. The CAGR for the Americas region will sit at 25.8%, and at 28.2% in APAC. 2022 and 2023 has, and continues to be, a difficult period for the U.S. and European collaborative robot market as a result of inflation and ongoing supply chain disruptions. Interact Analysis forecasts that EMEA will begin to recover in the second half of 2023 and into the first half of 2024, while recovery in the U.S. will take slightly longer, with a U.S. manufacturing downturn expected in 2024.
Most collaborative robot vendors are what Interact Analysis refers to as “pureplay” cobot vendors. This means collaborative robots are the only product line. Most of these are based in the APAC region, with Chinese vendors increasing share in the local market. South Korean manufacturers also have begun to emerge in the market since 2020, but success has been mostly tied to the local market because market entry is more difficult for overseas manufacturers.
Maya
Xiao, research manager at Inter-
act Analysis, said, “It’s promising to see that the application field for collaborative robots is widening. Maintaining this will be a key factor in future growth of the market. Deployment of cobots in the education, medical, logistics, catering and retail sectors is increasing due to the development of machine vision and machine learning software. The logistics industry offers enormous opportunity for the collaborative robot market due to the ability of robots to replace manual labor in areas such as picking, packing, loading/unloading and quality inspection. The market is set to enjoy steady growth over the next ten years.” ce
– Interact Analysis is a CFE Media and Technology content partner.
May automation mergers, acquisitions
THE BUNDY GROUP reported 15 automation transactions in May. The group reported 61 2023 transactions through May. Bundy Group is a CFE Media and Technology content partner and reports on mergers and acquisitions for Control Engineering, Plant Engineering and Industrial Cybersecurity
Bundy Group reported 15 automation transactions in May 2023. Click digital edition headline above for details. Courtesy: Bundy Group
Robot orders down in Q1 of 2023, vs. 2022
NORTH AMERICAN companies ordered fewer robots in first-quarter 2023 than for the same period last year. According to the latest report from the Association for Advancing Automation (A3), companies ordered 9,168 units valued at $597 million in Q1 2023, a 21% drop in total units and a 10% drop in value over the same quarter in 2022, which was the third-best quarter on record for North America. Automotive customers accounted for 68% of all robot orders in Q1, with 5,659 robots purchased. During Q1, non-automotive orders in consumer goods, semiconductor & electronics, plastics & rubber, life sciences/pharmaceutical/biomedical, metals, and others purchased 3,519 robots, down 42% over Q1 2022.
“While inflation and a slowing US economy may have taken a slight toll on robot orders overall, automotive companies continue to accelerate their purchases as they make the transition to manufacturing electric vehicles,” said Jeff Burnstein, president of A3 in a press release.
Labor shortages, reshoring inflation possible slowdown factors
Despite the state of the US economy, labor shortages, led by the manufacturing industry, remain the key driver in the growth of automation. As a result, more manufacturers continue to turn to automation, especially to handle the “dull, dirty and dangerous” tasks unattractive to human workers.
“In addition to labor shortages, we’re seeing many U.S. manufacturers bring more tasks back to North America as international labor costs continue to climb,” said Alex Shikany, vice president of membership and business intelligence. “Many find that the best way to bring manufacturing back quickly is to automate.” ce
–The Association for Advancing Automation (A3) is a CFE Media and Technology content partner.
Ways to improve organizational, technical readiness challenges for digital transformation
uManufacturers realize the benefits of digital transformation, but many are often ill-prepared to realize the benefits because of organizational and technical readiness.
Digital transformation for some companies has been like a tornado forecast with lack of preparedness for collaboration between information technology and operational technology (IT/OT) conflict. This has led to discontent with 8% of companies reporting satisfaction with their digital transformation project, said Mike Lashbrook, VP, digital solutions, JR Automation in his presentation, “Making Sense of the Madness: The Convergence of IT and OT Technologies on the Factory Floor,” at Automate 2023 in Detroit.
Why companies are dissatisfied
Lashbrook said many problems stem from a company not being ready from an organizational, technical or financial sense. Even if they are, they lack the tools and the abilities to unlock the data and make it valuable as a commodity for operations. The data funnel also is hoarded by leadership and IT and OT can be shut out of the process, which has been a source of traditional resentments. Lashbrook said management team members often don’t realize how expensive it is integrating current and legacy equipment.
Many companies start with technology, which Lashbrook said is the wrong approach. “The best place to start with is understanding your digital readiness. And that can be broken down to organizational and technical readiness.”
Organizational readiness
Lashbrook said companies are generally better along with the technical side of things because there have been more technology investments. The problem is
getting OT to buy into the concept and helping OT teams understand that digital transformation is worthwhile.
“Manufacturing operations should be leading the charge rather than IT because they know the challenge and see the value on the factory floor,” Lashbrook said. He said IT needs to be working hand in hand with OT and needs to be a strong voice, but it should be complementary and help OT.
That is especially true, Lashbrook said, if operators feel like they’re being challenged or dehumanized in the data collection process. The hinderance to engaging operators is a social rather than technical challenge.
“Engage them from the beginning, make them part of the solution process and do it in a way so they understand the technology being used,” he said. Once operators buy in, companies can accelerate learning through operator-generated data including:
• 4M (man, machine, method and material) information
• Production fluctuations
• Process time
• Standardized work loading
• Work scrolling/line balancing
• Ergonomics
• Error proofing
• Traceability, training
• Continuous improvement.
Human resources is an underrated and underused resource, Lashbrook said. HR teams can help companies understand the talent and workforce gaps. Business and process knowledge is held by the experienced workers, whom Lashbrook referred to as “oak trees,” because of their sturdiness and their deep roots of knowledge.
“The oak trees retain the knowledge,” he said. “What needs to happen is companies need to get the knowledge out of their heads and over to the younger workers.”
This article online (click the headline) has more about technical readiness. ce
Chris Vavra, web content manager, CFE Media and Technology, cvavra@cfemedia.com.
Mike Lashbrook, VP, digital solutions, JR Automation, suggested that humans and technologies can make digital transformation easier, at Automate 2023 in Detroit. Courtesy: Chris Vavra, CFE Media and Technology
RSA CONFERENCE 2023:
How to secure OT systems
ARE YOU TIRED of hearing how industrial control systems (ICS) are “insecure by default,” but if you buy this widget or tool, all of your problems will go away? On April 24 — the first day of the RSA Conference in San Francisco — Diane Golden, system security architect at Rockwell Automation, and Ahmik Hindman, senior network and solution consultant at Rockwell, attempted to help with their session, You Too Can Secure OT (operational technology).
The session attempted to help traditional information technology (IT) security personnel get started securing their OT systems. The speakers briefly highlighted the differences between OT and IT systems and then discussed a structured approach for managing OT security risk.
Taking a proactive approach to OT systems
The overarching theme was that organizations must leverage a holistic and proactive approach to industrial cybersecurity. They recommended starting with tools like the NIST Cybersecurity Framework, which begins with asset inventory. As the old axiom goes, you cannot protect what you cannot see. That means companies need an effective OT intrusion detection system. This should utilize both passive and active scanning, and be protocol specific and vendor agnostic.
Golden also mentioned that this risk assessment can help cash-strapped organizations get grants from federal and state governments for cyber resilience. There is money to be had for these efforts.
Hindman and Golden then walked RSA attendees through the basics of protecting OT/ICS systems. Many of their logical models employed commonly used industry standards such as the Purdue Model and IEC-62443.
Creating an incident response plan for OT systems
RSA Conference2023
Among speakers at a busy 2023 RSA Conference were DIANE GOLDEN and AHMIK HINDMAN of Rockwell Automation discussing OT cybersecurity strategies. Courtesy: Gary Cohen, Industrial Cyber-
This combination of passive and active scanning can help minimize false positives and help provide an agnostic inventory of OT, IT and the Internet of Things (IoT). High-level risk assessment is essential to help prioritize patches and compensating controls based on the common vulnerabilities and exposures (CVE).
How to manage vulnerabilities
With vulnerabilities, organizations can’t just say, “Let’s go patch everything.” There are simply too many vulnerabilities out there. Therefore, you have to look at cyber-physical impact on the OT side and ask some basic questions. Is your current risk level an acceptable risk level? What creates a bad day for you if it breaks? What are your crown jewels, the impactful things that can cause you a lot of downtime if they go offline?
Health, safety and the environment are clearly high-risk areas. If something can cause a fatality or an environmental disaster, it should get a great deal of your attention.
They concluded by talking about creating an incident response plan for OT. Most companies have an IT incident response plan, but many don’t have one for OT. That’s a problem. You need backup and recovery solutions that are proactive. You don’t want to be looking for them when something goes wrong because, by then, it’s too late. Golden said tabletop exercises are a great idea because many key players haven’t been involved in an OT security incident before. It’s essential to know who is supposed to do what when a crisis occurs. For example, if you have to decouple your IT and OT systems, who is authorized to disconnect them? They also suggested getting some third-party help. They recommended utilizing OT incident response retainers, or bringing in companies to help with OT response. But those companies give priority to customers who have them on retainer, so there is a need to plan in advance.
Golden mentioned that there are many free resources out there that can help. She specifically pointed out the Dragos OT-CERT platform.
The pair finished by imploring attendees that they too can:
• Automate OT asset inventory and vulnerability correlation
• Adopt an OT patch management strategy
• Implement mitigating controls supporting a defense-indepth strategy
• Develop an OT incident response plan. ce
Gary Cohen is senior editor/product manager at CFE Media and Technology, gcohen@cfemedia.com, Industrial Cybersecurity Pulse.
How the digital thread can improve manufacturing productivity
uTechnology is changing how products are being bought, purchased and interacted with and these advances are happening at an exponential rate. This growth, which didn’t seem possible a few years ago, is fueling a boom that is having major impacts, said Leslie Paulson, DVP, general manager, Servigistics Business Unit, PTC, at LiveWorx 2023 in Boston, in the presentation “Powerful Digital Threads Deliver Peak Service Outcomes.”
Advances are happening in “Everything from computing power to the changes in connectivity in the world, advances in artificial intelligence (AI) and more. It really is coming at an exponential rate, and it’s democratized. ChatGPT, for example, is available to anyone. It’s ubiquitous. And the rate of advance are going to increase as we get closer to quantum everything.”
The digital thread is designed to cut across an entire product’s lifecycle from conception to design to service. Courtesy: Chris Vavra, CFE Media and Technology
These changes go beyond technology developments, Paulson said. There’s a greater emphasis and focus on the customer in the product lifecycle. The lifecycle, she said, is a critical aspect of the digital thread, which covers the physi-
cal aspect, as well, and both feed off one another in a double loop.
“The companies that can glean the most insight across the digital thread will serve their customers better,” she said.
Break down information silos
The digital thread is designed to cut across an entire product’s lifecycle from conception to design to service. Paulson said information siloing remains a hurdle.
“Those silos are real. We need to work across these functions. If we did something better and the people responsible know what they need to know, wouldn’t we make better decisions?”
This is especially true with the services side of things, which plays a larger part of the asset’s lifecycle, Paulson said. “There are events that happen during the asset’s
lifecycle, and we need to understand it because otherwise we won’t service it well.” The added benefit, she said, is by keeping an asset in service for as long as possible exponentially improves its value over the long term. That’s only possible if all the information is accessible.
Going beyond the individual asset, this can be applied to the entire service landscape, and it can be integrated.
“There’s a lot of capability and tools that can drive powerful results,” Paulson said. “At the beginning, though, we have to deliver the basic information points, and we need to be able to optimize the service parts in a way so the right part is in the right place,” Paulson said. “We have to maximize availability and minimize costs.” Paulson said companies will fare best if they empower the critical stakeholders with the right information.
Data capture, integration, use
Aly Pinder, VP, IDC aftermarket services strategy, said companies’ main pri-
orities remain efficiency and satisfaction. This is even more important, he said, as companies realize they need to improve customer service and employee experience. That’s not always easy because there are worker shortages and other
‘ Data is only as valuable as the people who have access to it.’
challenges that limit companies from sometimes reaching their full potential.
The challenge, Pinder said, is more than half of devices are not connected. “The goal is to get more connected, but how do we get there, and what do we once we get it?”
Pinder mentioned how companies can go from a break/fix reactive mindset to a prescriptive mindset. He said it’s not practical for all companies to go
prescriptive, but they should strive to be more in that direction along with predictive and preventive.
“If you’re going to be reactive because it works, [then] be better” while doing so, Pinder suggested. “Make sure the worker has all the info” needed.
Information is one of the most — if not the most — valuable commodities, but Pinder said that is only part of the equation. If the information is siloed and restricted, then it doesn’t matter much. The same is true when it comes to creating a service model that maximizes the value of the products. He encouraged companies to start now and focus on the short-term wins with an eye toward the long-term transformative views.
“If you have data, it’s only as valuable as the people who have access to it.” ce
Chris Vavra, web content manager, CFE Media and Technology, cvavra@cfemedia.com.
Additive manufacturers stretch capabilities with digitalization, motion control
uAdditive manufacturing (AM) and other 3D printing technologies advances were showcased at Rapid + TCT, an exhibition and conference sponsored by SME, at McCormick Place in Chicago. Additive manufacturing, which involves the construction of a 3D object from a computer-aided design (CAD) model or a digital reconstruction, has gone through many evolutions over the past several years. Improvements continue in the types of materials used, and researchers from all over keep making new composites designed to be sturdier, stronger and more durable.
What was new at Rapid, in line with other industries, is how additive manufacturers are trying to better control of the lifecycle process including materials, design, creation and integration.
“We want to be a full-end business and
Media and Technology
provide end-to-end design for our customers,” said Rich Stephenson, AM business development at Siemens. “Whether it’s physically or digitally, we want to give consumers the full digital thread.”
He mentioned the Charlotte Advanced Technology Collaboration Hub (CATCH), which serves as an ecosystem and a place where people can see how the process works and make it less abstract.
David Lakatos, chief product officer for Formlabs, described their production process as more about ensuring they control all aspects of products they make.
“We’re about more giving more access to those who make physical products in a professional sense,” he said. “That’s important to us because we want to work with people who are professionals and are serious about this and want to improve.”
Formlabs’ Form 3+ Basic Package 3D printer was designed for the engineer looking to mass-produce items they might need for day-to-day operations.
In critical power facilities a power loss is COSTLY. When your facility has Sequence of Event Recorders from Cyber Sciences installed, you can quickly identify the root cause of the incident and any sequential cascading events. This provides a clear picture of what happened, and what is needed to restore power faster. With our solutions in place, you can relax knowing we are keeping watch over your critical applications.
The Form 3+ Basic Package 3D printer by Formlabs was designed for the engineer looking to mass-produce items they might need for day-to-day operations. Courtesy: Chris Vavra, CFE
Enhancing with digital twins
Austin Corder, content marketing generalist for Lumafield, explained how an X-ray scans the part while spinning to produce thousands of images to create a representation of the model, which is reconstructed through an algorithm to a 3D model. He demonstrated a Lithium-ion (Li-Ion) battery reconstructed through this model.
“It’s about safety to scan,” Corder said. “We went to ensure all layers are exactly right, so there aren’t any gaps.”
If there are unintended gaps during the printing process, the algorithm will help them find the gaps so they can be filled in, Corder said.
Andy Stults, senior sales application engineer at Nikon Metrology, discussed a similar process when it comes to quality inspection. “You can scan and reverse engineer a part and make a surface, and then you can make a part from this.”
Online
controleng.com
What systems integrators, others should expect in the second half of 2023
How to protect smart machines from cybersecurity attacks: Automate 2023
Industrial Cybersecurity Pulse: RSA Conference 2023: The cybersecurity impact of AI tools like ChatGPT
Scaling Industry 4.0 transformation for the future
ProMat 2023 exhibits show what is possible in warehouse automation, motion control
More answers on how to digitalize an OTdata infrastructure
More answers about how to build a better HMI with collaborative, modern, cloud technology
More answers about control system integration advances competitiveness
MIT engineers grow atomically thin transistors on top of computer chips
SHOWS, CONFERENCES
June 18-24, 2023 Honeywell Users Group (HUG), https://pmt.honeywell.com/us/en/ about-pmt/honeywell-users-group
June 24-27, EASA 2023 Convention and Solutions Expo, https://easa.com/convention
Sept. 9-11, Pack Expo Las Vegas 2023, PMMI, https://packexpolasvegas.com
Sept. 26-28, Ignition Community Conference, Inductive Automation
https://inductiveautomation.com/resources/icc#
Cindy Kutchko, additive manufacturing director for PPG, said they use digital twins and modeling to help improve the precision and quality of its products. This is especially important because many of PPG clients are in the aerospace industry, which requires absolute precision. Even a
tiny mistake can lead to serious injury or death. Creating a digital model helps in that journey. ce
Chris Vavra, web content manager, CFE Media and Technology, cvavra@cfemedia.com.
4 ways to fill the manufacturing skills gap
Filling the skills gap in manufacturing requires participation. This is not someone else’s challenge to resolve. Here’s how you can help.
Curing the causes of the skills gap in manufacturing requires participation. To those thinking again about this challenge and considering next steps, thank you. To those retiring in the next 10 years: Share your know-how now so your knowledge can live on.
1. Dispel dull, dirty and dangerous myths
Enlighten understanding about manufacturing careers among youth and dispel myths. Perceptions of manufacturing as a dull, dirty, dangerous and as a low-paying career are incorrect. Where jobs are dull, dirty and dangerous, practical uses of automation are improving safety and job satisfaction. Many manufacturing plants look more like hightech labs. Manufacturing wages are increasing to gather the best talent and encourage those from other career paths to participate in automation, controls and instrumentation, a hugely satisfying career. Talk about and show this to youth at every opportunity.
2. Enable career paths by providing budgets, tools, embodiment of knowledge
Return on investment (ROI) for investments in automation, controls and instrumentation extends beyond the integrated automation hardware and software. Add quantifications for safety and people saved from leaving through boredom by taking on more interesting and skilled positions working with automation (rather than performing dull, repetitive work). New, updated workflows and tools encourage younger generations to take interest and retain interest in rewarding careers with automation. Integrate legacy knowledge into new processes and technologies before retiring.
3. Share knowledge through articles, software and mentoring
By sharing knowledge in articles, embedding knowledge of workflows, products and processes in your local software and through mentoring younger peers, you learn from them and create a legacy that will live on to benefit the world well beyond your career (and possibly your lifespan). Let your lifetime of knowledge live on.
4. Encourage use of trusted tools like Control Engineering
Part of mentoring includes sharing the “secret sauce” with those around you. Control Engineering has adapted with the times by continuing to research and cultivate and share critical information about automation, controls and instrumentation across about 65 industries. Think again about how you can help us help the world. ce
Mark T. Hoske is content manager, Control Engineering, CFE Media and Technology, mhoske@cfemedia.com.
3010 Highland Parkway, Suite 310, Downers Grove, IL 60515. 630-571-4070, Fax 630-214-4504
Content Specialists/Editorial
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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
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
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
KEYWORDS: Control Engineering, automation, instrumentation, education, skills gap
LEARNING OBJECTIVES
Pitch in to help fill the skills gap by dispelling dull, dirty and dangerous myths.
Share knowledge through software, mentoring, articles and use of trusted tools like Control Engineering
Enable career paths by providing budgets, tools, embodiment of knowledge.
CONSIDER THIS
Think about the next two generations in automation.
ONLINE
With this article online (click the headline in the digital edition) to find six links to related articles. Also browse here: https://www.controleng.com/ system-integration/workforce-development Online controleng.com
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.)
* If the content meets criteria noted in guidelines, expect to see it first on our Websites. Content for our e-newsletters comes from content already available on our Websites. All content for print also will be online. All content that appears in our print magazines will appear as space permits, and we will indicate in print if more content from that article is available online.
* 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
The best automation, control and instrumentation products, as selected by engineers
Winners of the 36th annual Control Engineering Product of the Year* awards include industrial artificial intelligence software, a fanless and rugged embedded computer optimized for edge computing and a terminal block that accommodates direct insertion of all conductor types, among other notable technologies. This year, companies submitted their new and improved products debuted between November 1, 2021, and December 31, 2022, to be judged for this distinguished honor. Then readers whittled them down to 42 winners, including the 2023 Most Valuable Product, which received the most votes overall. Full descriptions of the winners of the 2023 Control Engineering Product of the Year program are available, along with official rules via: www.controleng.com/events-and-awards/product-of-the-year.
Entries for the 2024 program will open October 1, 2023; eligible products include those first introduced to the North American market within the 2023 calendar year.
Amanda Pelliccione is the research director and project manager of awards programs for CFE Media and Technologies and its publications, including Control Engineering.
*From 2006 to 2022, this program was titled the Engineers’ Choice Awards; 2023 is the first installment of the program under its new title, Product of the Year. See the FAQs page for more information.
ANSWERS
Judith Ponniah and Geeta Perhwani Sr., AspenTech
How to use a lifecycle digital twin to streamline carbon capture processes
A lifecycle digital twin for startup, commissioning and operations can help with sustainability technologies, such as carbon capture, storage and utilization. Save up to 20% in capital expenditures and 15-30% in operational expenditures.
MOnline controleng.com
KEYWORDS: Digital twin, carbon capture
LEARNING OBJECTIVES
Learn how a lifecycle digital twin can help improve outcomes for sustainability initiatives.
ONLINE
Digital tools help with sustainable, greener designs
https://www.controleng.com/ articles/digital-tools-help-withsustainable-greener-designs/ Digital twin improves plant design and operational performance
ost companies fall short of capital project expectations for return on investment, but using a lifecycle digital twin provides process optimization more quickly, resulting in capital expenditure savings of as much as 20% and operational savings of 15-30%. Industries are faced with unpredictable market requirements, and stakeholders are finding projects chronically behind schedule or over budget. As a result, they are seeing missed market opportunities and decreased asset profitability. Asset intensive industries are investing in digital technologies to create contingency plans, manage execution, optimize construction sequences and prevent budget and material overruns. In addition, they are reviewing assets from a sustainability outlook, garnering support from the public and financial institutes as they promote sustainability in the design and work process to increase energy efficiency while reducing waste and emissions.
To achieve a more effortless execution, the solution method must be simple and frictionless. The common issue facing engineering service companies and owners is that the current digital technologies do not focus on the overall project lifecycle aspects, necessitating the need for multiple digital technology solutions to achieve sustainability and profitability goals during an asset’s lifecycle.
Digital twin technology
The industry needs a holistic solution that starts in design and is used throughout start up,
commissioning and operations. It can become the cornerstone for the implementation of more digital solutions to support predictive maintenance, spare part inventory, advanced process control and supply chain optimization.
Digital twin provides the complete solution from a bird’s eye view that’s necessary for different applications and use cases, whether greenfield or brownfield. No matter where in the digital transformation journey a company is, a digital twin can be easily implemented to help improve asset performance with advanced visualization. An offline digital twin during the early project phases allows engineers to design the most optimized, lowest capital expenditure (CAPEX) process. An online digital twin delivers previously unattainable critical insights to optimize operations while dealing with ever-changing environmental regulations.
As industries pivot to meet ambitious net-zero targets, the energy transition projects are bringing in new opportunities for licensors and engineering, procurement and construction (EPC) firms. Licensor and EPC firms can help owners secure the benefits from a holistic digital twin model by transferring this digital twin from the feasibility stage, to final investment decisions, through operations and maintenance.
Digital twin for carbon capture
Carbon capture is one of several imminent technologies helping organizations meet their sustainability goals faster in efforts to transition to a more decarbonized economy. Leading companies seek solutions that can help support tactical, strategic and business decisions through key phases of design and operations. Organizations supporting greener and newer technologies such as carbon capture, storage and utilization (CCUS) can alleviate growth pains through implementation of a lifecycle digital twin. This holistic approach helps with increasing project feasibility and risk mitigation. A lifecycle digital twin
can support organizations by providing insights into new technologies and making informed decisions for each phase of the asset life.
• Investment decisions: Technology evaluation takes place during initial conceptual design of a project to assess potential technologies available for adoption. Based on future energy and renewables prices and emissions targets, many capture technologies are available. Low-carbon hydrogen production is accelerating momentum towards carbon capture projects. With a diversified mix of available technologies, investors are challenged with evaluating tradeoffs between the return on investment (ROI) and total CO2 captured. Digital technologies help investors examine different system configurations to identify the conditions where risk across the CCUS system is minimized including the efficiency gained through scale and integration of system components. For carbon capture employed to achieve low-carbon hydrogen, more energy and process efficiencies can be gained.
• Risk and planning: Models can provide insights to compare available technology options quickly for technical and economic feasibility, reducing and quantifying the risk associated with CAPEX investment. Better insights enhance collaboration between investors and other key stakeholders, aiding with informed selection of the best technology to support organizations with long-term profit and sustainability goals. Amine-based absorption for carbon capture is a mature technology, but it is energy intensive, hence necessitating new solvents innovation to find the balance between energy and CAPEX investment.
• Scenario analysis for conceptual design: Scenario analysis is crucial for exploring possible financial outcomes based on different factors. With
the business environment being ever-changing and filled with uncertainty, conducting regular whatif scenario analysis will allow organizations to see how different internal and external inputs might cause business key performance indicators (KPIs) to change. This can help organizations make proactive planning decisions that account for a range of positive and negative possibilities in design.
Most projects involve engineers using multiple files to represent various scenarios with topological differences. Inputs are manually changed in a series to better understand the system. All these steps are time consuming and error prone.
Process simulator models integrated with economics can help to perform techno-economic evaluation through rigorous modeling of the carbon capture process. Robust process simulators (and associated integrated workflows incorporating safety and layout) help innovate and drive down CAPEX by up to 20% and operational expenditure (OPEX) by 15-30%. Offline digital twin models offer agile workflows to quickly run thousands of scenarios in parallel while leveraging high performance computing or cloud-based parallel computing, as well as artificial intelligence (AI) and visualization tools for data analysis. Scenario analysis can provide early visibility into how design decisions may constrain feedstock selection, environment and climate impact, equipment availability, reliability and maintenance strategies. These early insights into identification of process operation strategies enable stakeholders to make better decisions for profitable and sustainable operations.
• Front-end and detailed sesign: After technology has been selected and finalized, a robust design
ORGANIZATIONS supporting greener and newer technologies such as carbon capture, storage and utilization (CCUS) can alleviate growth pains through implementation of a lifecycle digital twin. This holistic approach helps with increasing project feasibility and risk mitigation. Courtesy: AspenTech
ANSWERS
‘ Examine sustainability in the design and work process to increase energy efficiency while reducing waste and emissions. ’
becomes essential for seamless startup and operations.
As process decisions made early on lock in capital costs, a collaborative front-end tool that digitalizes front-end engineering deliverables lowers the risks of late design changes through transparency across disciplines, ensuring communication of each change.
A front-end digital twin lets organizations visualize 5-dimensions (5D) of the project early in the design phases. Early visibility into 3D layout plus cost and schedule at the design stages allows organizations to make informed decisions to improve sustainable outcomes, avoid project risks and estimate the impact of proposed changes in the design. Get this visibility through conceptual layout, conceptual cost and schedule modeling. This can help avoid dealing with change orders and project overruns, hence eliminating financial risk associated with upcoming high value sustainability projects. Eliminating the delays early in the design have helped companies accelerate the project duration by nearly 20%. In addition, 5D visibility with front-end digital twins have helped organizations select the design concepts 87% faster.
Insightsu
Digital twin insights
u An offline digital twin during the early phases of a project allows engineers to ensure an optimized, low capital expenditure (CAPEX) design process.
uCarbon capture is one of several imminent technologies helping organizations meet sustainability goals faster as we transition to a decarbonized economy.
u By using a digital twin from feasibility to operations, organizations can align quickly on goals of sustainability and operational excellence while reducing risks to production.
• Startup and commissioning: During start up and commissioning, robust digital twin models that are already prepared validate the process control system and the operating guidelines, enabling faster operator training. Running a digital replica in parallel with the actual plant operation creates a valuable means of training operators and technicians to familiarize them with the control schemes and processes before start-up in an offline and risk-free environment. Making them better equipped to successfully control any process upsets or abnormal operational situations by rehearsing such events. For newer, complex processes such as point source and direct-air capture (DAC) technologies for carbon capture, which have less than 30 operating facilities, proficient training and expertise is crucial to lower risks.
• Operator training system: With the industry struggling to attract talent and much of the experienced workforce heading to retirement, ensuring operators can practice in the safety of an office environment — or remotely if they choose — is essential to reducing risk, enhancing production and attracting a new generation of skilled workers. Also, adding technologies such as carbon capture requires experienced operators to revise their training. Companies are seeking dynamic ways to train employees quickly and efficiently. Software simulator-based
digital twins have been expanded into using augmented reality (AR) and virtual reality (VR) to speed up learning through an immersive and scenariobased virtual environment. Operators can now perform multiple scenarios in a simulation environment which mimics high stress conditions and allows for object recognition. Sophisticated technology and digital twins help companies close the talent gap and allow for a seamless approach to reducing training costs and mitigating operator driven risks.
• Operations and maintenance: Once the plant is operational, the accuracy of the digital twin can be consistently enhanced with plant data taken directly from the process as it becomes available. This real-time online digital twin model provides critical insights into operations for continuous monitoring of equipment and increased plant performance. Greater insights into equipment health helps operations to avoid risks associated with unscheduled downtime. Online digital twin models can be used to optimize process control targets to maximize captured CO2 and minimize energy consumption to reduce total capture costs based on the current process inputs.
Carbon-capture processes
Capital project success is critical to keep companies competitive and profitable, especially during trends of market instability or volatility. Digitalization helps meet these business goals, making new and sustainable technologies easily accessible and cost friendly. Using a digital twin from feasibility to operations, organizations can align quickly on goals of sustainability and operational excellence while reducing risks to production. Digital twin is more than just a visual, virtual representation of process, operation, or system. It is an approach that aligns with industry needs to enable collaboration, transparency and improvements across an asset’s lifecycle.
A lifecycle digital twin then becomes a holistic solution for new and sustainable technologies, including, but not limited to, carbon capture, hydrogen, biofuels, bio-feedstocks and process improvements associated with circular economy. ce
Judith Ponniah is industry marketing director, AspenTech and Geeta Pherwani Sr. is product marketing manager, AspenTech. Edited by David Miller, content manager, Control Engineering, CFE Media and Technology, dmiller@cfemedia.com.
Martin Gubow, Keysight Technologies
How wireless TSN can be a common foundation for innovation
Standards and implementation for Wi-Fi and 5G support time-sensitive networking. Table compares industrial wireless and wireless TSN capabilities.
Recent advances in Wi-Fi and 5G have made it clear that wireless networks are capable of supporting time sensitive networking (TSN)-grade performance. Benefits for wireless TSN (WTSN) in industrial automation include flexible deployment, reduced maintenance costs, reconfigurability and mobility.
Over the next few years, we can expect accelerating adoption of WTSN infrastructure for closedloop control, industrial robots, automated guided vehicles, and other industrial applications. WTSN is a key enabling technology to make Industry 4.0 implementations more nimble and efficient.
While WTSN capabilities are coming to industrial networks, they won’t all roll out at once or meet exactly the same key performance indicators (KPIs) as wired networks.
Avnu Alliance, a community open to organizations interested in advancing the deployment of TSN-based open standards, released a white paper outlining key performance indicators (KPIs) for WTSN applications, including industrial robots and closed loop control as well as real time media transport for live events and AV/VR systems.
Focusing on time synchronization, bounded latency, reliability, security and capacity, the white paper outlined the most crucial aspects of WTSN applications and identified broad requirements representative of overall market expectations.
Common ground in wireless time-sensitive networking market expectations
As we researched the market expectations of diverse industries, a very interesting theme emerged: Despite a wide range of typical service areas and a variety of traffic profiles, KPIs for
industrial applications are broadly similar to those for other high-priority WTSN applications.
WTSN applications also are expected to adhere to industry-recommended security best practices, including with respect to authentication, integrity, confidentiality, availability and resiliency to potential interference or attacks.
Many wireless applications, across different markets, can be addressed with a time-synchronization accuracy requirement of about 1 µsec, which is within the current capabilities of 5G and Wi-Fi networks: IEEE 802.AS clock synchronization is enabled by the current release of the IEEE 802.11 Wi-Fi standard and supported by 3GPP Rel 16.
Bounded latency requirements for wireless applications are often 10 ms or less, making traffic shaping another high priority feature for WTSN. TSN traffic shaping is enabled by the IEEE 802.1Qbv (Time-aware shaper) standard. IEEE 802.1Qbv defines a set of timed gates to control the queues associated with multiple traffic classes on an TSN bridge. It offers predictable data delivery performance, which is critical in industrial use cases. IEEE 802.1Qbv can operate in combination with the latest Wi-Fi scheduling capabilities available in Wi-Fi 6/6E and 5G systems.
All high-priority WTSN use cases have reliability requirements well in excess of general consumer or workplace network applications. In the timeand safety-critical scenarios common to Industrial applications, reliability can be ensured via the IEEE 802.1CB Frame Replication and Elimination for Reliability (FRER) standard. FRER uses data replication on multiple paths, reducing the impact of individual device/link failures. FRER is transparent to the MAC/PHY network layers, so it can function
Understand how wireless timesensitive networks (WTSN) can help manufacturers improve communications.
Learn about the different standards required for WTSN. Learn how converged networks can let different data traffic exist on the same physical network.
ONLINE
See additional wireless stories at https://www.controleng. com/networking-and-security/ wireless/
CONSIDER THIS
What considerations do you have for wireless networking at your facility?
‘ Converged industrial networks with multiple traffic types and classes, including wired and wireless, time-sensitive and timeelastic, reliable and losstolerant applications. ’
Insightsu
Wireless TSN
uWireless timesensitive networking (WTSN) offers many benefits such as flexible deployments, mobility and reconfigurability, which are crucial in manufacturing environments as operations become more mobile.
uWTSN applications have to adhere to strict security best practices when it comes to authentication, integrity, confidentiality and more. This is needed as modern manufacturing devices often have internet capabilities built in or as legacy devices are given internet connectivity.
on either 5G or Wi-Fi wireless networks, though implementation may differ across system types. There is common ground among WTSN applications across industries, which means these similar base requirements mean a larger addressable market for silicon and device manufacturers, speeding the pace of industry innovation. It also means WTSN network could support multiple different traffic types. This is likely the future: Converged industrial networks with multiple traffic types and classes, including wired and wireless, time-sensitive and timeelastic, reliable and loss-tolerant applications.
Mixed criticality industrial networks, wired and wireless
Converged networks will allow different data traffic to coexist on the same physical network, across wired and wireless mediums. True convergence will enable the management of multiple traffic types on the same wire, allowing more efficient infrastructure and network management. That’s desirable, but it’s not straightforward. Converged networks will require the exchange of different classes of traffic and the coexistence of different traffic types and devices, all managed by IT, OT and media professionals.
Plugfests, demonstrations to verify wired, wireless TSN interoperability
Avnu Alliance plugfests, demonstrations and test plans help verify performance and interoperability of wired and wireless TSN devices. During the 8th annual TSN/A Conference in Stuttgart, Germany, Avnu hosted demonstrations in its booth of TSN tests for IEEE 802.1AS and IEEE 802.1Qbv. Tests were run on the Avnu Express Test Tool and on Keysight’s new TSN Test Tool. Demonstrations included wired and wireless TSN tests. Avnu Alliance presented at Wireless Congress 2022 in Munich on WTSN Interoperability Testing and Integration with Wired TSN. The events help teach how wired and wireless TSN systems may be built, configured, and verified. Silicon vendors, network infrastructure providers, and device manufacturers also are encouraged to join Avnu Alliance to add to the verifiable TSN toolbox. ce
Martin Gubow, TSN program manager, Keysight Technologies. Edited by Chris Vavra, web content manager, Control Engineering, CFE Media and Technology, cvavra@cfemedia.com.
TABLE compares industrial wireless and wireless TSN capabilities. Courtesy: Keysight Technologies, an Avnu Alliance member
Remote wireless devices connected to the Industrial Internet of Things (IIoT) run on Tadiran bobbin-type LiSOCl2 batteries.
Our batteries offer a winning combination: a patented hybrid layer capacitor (HLC) that delivers the high pulses required for two-way wireless communications; the widest temperature range of all; and the lowest self-discharge rate (0.7% per year), enabling our cells to last up to 4 times longer than the competition.
Looking to have your remote wireless device complete a 40-year marathon? Then team up with Tadiran batteries that last a lifetime.
ANSWERS
John Clemons, Rockwell Automation
Digital transformation benefits
Digital transformation can help companies realize long-term business benefits, but it takes dedication and strategy to actually transform.
Digital transformation is two words for a many ideas centered around digital technologies and tools. Digital transformation initiatives help manufacturing companies accelerate business growth through digital technologies and use these tools to transform operations to make them more productive, increase overall product quality and ensure regulatory compliance. They also can use digital tools to transform the shop floor workforce into highly skilled knowledge workers.
becoming part of advanced analytics and machine learning (ML) solutions. AI is everywhere.
• AR/VR has very diverse uses in manufacturing, such as expert capture, machine troubleshooting, equipment maintenance, work instructions, changeover instructions, quality tests and a lot more.
• Digital twins are used to create digital duplicates of sophisticated equipment and processes on the shop floor and are used for optimization, troubleshooting, training, maintenance (especially condition-based maintenance), continuous improvement and more.
• Cloud and edge computing are bringing simpler information technology (IT) and operational technology (OT) architectures to bear while providing more flexibility and agility while being cybersecure.
KEYWORDS: digital transformation
LEARNING OBJECTIVES
Understand digital transformation’s potential role in manufacturing’s present and future.
Learn why some companies have been resistant to digital transformation.
Learn about what transformative benefits digital transformation can deliver.
ONLINE
See additional digital transformation stories at https://www.controleng. com/digital-transformation/
CONSIDER THIS
How has digital transformation transformed your company? Online controleng.com
Transforming manufacturing with digital tools can help companies become sustainable, socially responsible and profitable. Fundamentally, digital transformation is the idea digital tools and technologies can transform these aspects of manufacturing operations and provide a significant bottom-line benefit to the business.
Smart digital transformation
Manufacturers now have access to myriad digital tools and technologies that support digital transformation efforts. These different technologies, devices and systems are being integrated, creating value far greater than the sum of their parts.
The industrial Internet of Things (IIoT) applied the IoT to manufacturing, providing a communications backbone for everything in the plant. Artificial intelligence (AI), augmented reality/virtual reality (AR/VR), big data, digital twins, cloud and edge computing, manufacturing execution systems (MES), enterprise resource planning (ERP) and many other smart manufacturing solutions are all built on, or have access to, the IIoT foundation. For instance:
• AI is now becoming a part of almost every aspect of manufacturing. It’s being built into controllers and
• The latest generation of MES and ERP systems impact the entire enterprise by serving as data repositories and supporting the digital tools and the digital transformation technologies.
Many other available technologies leverage digital transformation, such as additive manufacturing, collaborative robots, identification technologies, energy storage capabilities and mobility technologies.
The technologies needed for digital transformation are available today and they work very well. The challenge is deciding which digital transformation technologies to use. It’s also tempting to try to use all at the same time, which isn’t practical. Digital transformation is wonderful, but use it wisely.
Too many pilot projects?
When digital transformation was first talked about several years ago, the best advice seemed to be to start with a pilot project. That always seems like good advice when talking about new technology. Prove the technology and benefits. Get people to adopt the new technology and use it successfully before expanding.
The problem is the whole manufacturing industry now seems to be in pilot mode. Everyone is piloting new technology. Many manufacturers are running multiple pilots with multiple technologies. They are then running more pilots behind them. It seems like the manufacturing industry
has become nothing but ongoing pilot projects where everyone is waiting for the results of one pilot before yet another one is considered.
The idea of transformation is just that — to transform. It is not an easy or straightforward process. A synonym for transformation is metamorphosis, which is a transformation but from an immature form to a mature one. No one really wants to embrace transformation and make big changes. They are looking for small changes, driven by small pilots, in an incremental fashion to get them where they want to go. For most companies, that is not going to work. Transformation is what’s needed.
Performing pilot projects without the transformation, or the metamorphosis, doesn’t really produce the business benefits. There often are some business benefits with pilot projects or they’d be shut down very quickly. There are no transformative benefits, which only come from a true metamorphosis, which can only be achieved from completely changing the way the business is run. That is the shortcoming when companies try to digitally transform but don’t maximize the technological capabilities to the fullest. Many pilot projects succeed, but very few are truly transformative successes where digital tools created a true metamorphosis for the business and delivered significant business benefits.
Embrace change, transformation
The number one thing needed for the manufacturing industry to get out of pilot mode and embrace
digital transformation, despite the probable mess and stress. It is time to go all in and digitally transform the manufacturing business to achieve a total metamorphosis from an immature state to a mature state.
Manufacturers can use digital tools to transform the business and accelerate business growth, while creating new ways of doing business to serve customers. They can increase productivity by eliminating processes, paperwork, non-value-added steps, redundant activities, waste, defects, breakdowns and delays. They can develop products existing customers don’t even know they need or use data to develop products for new customers they would not have considered.
It’s also about transforming the shop floor workforce from manufacturing labor into highly skilled, highly trained knowledge workers who know the value of information and always have the right information at the right time. They have skills required to make manufacturing function efficiently and keep it running to do what is needed and when.
Digital tools can transform manufacturing to be truly sustainable with zero emissions and no environmental impact. This leads to being a socially responsible and valued member of the local community and a valued citizen of the world while creating value for company customers, employees and shareholders. ce
John Clemons is a solutions consultant, LifecycleIQ Services at Rockwell Automation. Edited by Chris Vavra, web content manager, Control Engineering, CFE Media and Technology, cvavra@cfemedia.com.
‘
Manufacturers can use digital tools to transform the business and accelerate business growth, while creating new ways of doing business to serve customers.
’
MANUFACTURERS use digital tools to transform the business and accelerate business growth while creating new ways of doing business to serve customers. Courtesy: Rockwell Automation
ANSWERS
Frank Lamb, Automation LLC
Robotics troubleshooting and maintenance advice
Robotics troubleshooting requires the user to understand many ways machines operate.
Industrial robots are used in manufacturing and material handling tasks, and their physical configuration depends on the function that is required.
Payload and speed requirements help determine the type used in a particular application.
Robots can have up to 6-7 axes of motion or as few as 3. Two axes are required to reach any point in an X-Y plane, and 3 are required to reach any point in X-Y-Z space. To control the position of tooling at the end of the “arm,” three more axes are required in addition to X, Y and Z, these are pitch, roll and yaw.
Figure 1 shows the six axes required to reach any point and orientation in three-dimensional space, but robots use different coordinate systems and joint configurations can differ. The origin and directions are defined differently depending on the
brand and can often be changed in the software.
The X, Y and Z locations are referred to as Cartesian coordinates, but they can be defined from different reference points. If defined from the base of the robot or reference point of the environment, they are referred to as world coordinates. In this case the origin’s reference is stationary. When addressed from the view of the manipulator, they are referred to as tool coordinates, where the origin moves with the end effector. This may also include an offset, from the point where the tooling is attached to where it contacts the part. Local coordinates also can be defined, usually with origins within a working area. This allows references to be duplicated for pallets or other local systems.
Individual joints can also be controlled independently, usually defined in degrees. Distances are generally defined in metric measurements (mm) but also can be scaled to user defined units in the software.
In addition to X, Y and Z, roll, pitch and yaw may be defined by other letters like U, V and W.
The area which a robot can reach is called the work envelope. Planes and boxes can be defined within the envelope to prevent collisions or for safety purposes, safety devices such as light curtains also can be integrated into a robot workcell.
Path awareness for robots
Robot controllers constantly perform calculations to ensure they know where the robot is relative to defined points and paths. Axes must work together when maintaining positions along a defined path, so a robot is the ultimate form of coordinated motion control. This is why controllers are generally dedicated to the task of achieving and maintaining position.
An important problem to understand when dealing with robots is that of a singularity. In this case,
the robot cannot move its end effector along a certain path due to either physical or mathematical constraints. Robots can end up in positions where it cannot rotate the tooling around certain positions, this is sometimes referred to as gimbal lock. There are other physical configurations where moving joints through certain orientations can damage associated cables or hoses, so care is needed when moving robots close to singularity points or rotating axes too far. There are usually multiple joint configurations that can achieve the same tool position and orientation, often referred to as redundant degrees of freedom.
Robot controllers are often able to perform logic functions and operate external equipment, but usually they are built into workcells and connected to a “master” controller, such as a programmable logic controller (PLC). The controller may be a separate unit connected to the robot with power and signal cables or be built into the robot base. Connections may be physical 24 Vdc, communication links, or “pass through” ports and connectors with internal routing to the end effector or tooling. Pass through ports often include pneumatic hoses.
Robots can be categorized by their physical configuration. Figure 2 shows some of the common types of robots used in industrial applications.
The 6-axis articulated arm is very common in applications with heavy payloads, whereas the 4 axis SCARA is often used for oriented pick-and-place. The Delta configuration is very fast and often used in the electronics industry for component placement. An additional term to be aware of is a collaborative robot (cobot). They are designed for direct human interaction within a shared space and have a different configuration than those shown here.
Easier robot programming
Robots can be programmed using a computer or by means of a teach pendant. Two types of code need to be programmed, procedures and positional data.
For a task where a robot end effector needs to move from one location to another, the starting and end points need to be defined, then a procedure needs to be written on how to get there. This may involve additional positions, along with external signals telling the robot an object is present or to begin the move.
Positions can be defined by listing them in the software, but using a pendant is easier. A teach pendant allows an operator to move individual axes, “driving” the robot to the desired location. A low speed is usually used for precision and safety. A 3-position “deadman switch” also needs to be pressed while the robot is being maneuvered.
Continued on page M5
FIGURE 2: Common robot types include 6-axis articulating arm (left), SCARA (center) and Delta (right).
KEYWORDS: motion control, robotics ONLINE
With this article online (click the headline in the digital edition), find more on: Considerations for robotic troubleshooting, maintenance
Find more motion control and robotics stories at https:// www.controleng.com/ mechatronics-motion-control/ CONSIDER THIS What are the most challenging aspects of motion control and robotics maintenance you face?
FIGURE 3: Robotic workcell example.
ANSWERS
Doug Schuchart, Beckhoff Automation
How automation storage and retrieval systems will shape the future of distribution operations
OPEX
discusses the importance of EtherCAT and safety technology in optimizing its scalable, high-performance system.
AKEYWORDS: AS/RS, intralogistics
LEARNING OBJECTIVES
Learn how effective traffic management and real-time communications among warehousing system robotics are enabled.
Understand how a compact industrial automation safety controller can separate a storage grid into multiple zones, each of which can be deactivated while others continue operation.
How can you enable easier scalability in logistics?
mong the many intralogistics software and technology products available, the automated storage and retrieval system (AS/RS) has become a staple. Companies of all sizes and industries rely on AS/RS to enable modern warehousing and fulfillment. OPEX released its Infinity system at MODEX 2022. This next-generation goodsto-person (G2P) system is said to offer top-tier storage density, modularity and flexibility. Using wireless Infinity iBOT robotic vehicles, triple-deep tote storage and the OPEX Cortex software platform, Infinity delivers the right SKU to the right workstation every time, increasing storage capacity by 35% while making bot paths up to 65% more efficient.
Beckhoff spoke with Monty McVaugh, OPEX manager of product management, to explore Infinity technical differences. The EtherCAT industrial Ethernet system and other automation technologies play an important role in meeting OPEX fulfillment requirements with sustainability in mind.
Q: Why are AS/RS systems needed?
Monty McVaugh: First, ongoing labor shortages and rising labor costs mean companies need to leverage their existing workforce efficiently and safely. This means they are not continually walking the warehouse aisles and climbing ladders to manually pick parts, which leads to burnout. Second, the cost of warehouse real estate is at an all-time high, so companies need to optimize how they use each square foot. Next, inven-
tory security is critical, especially in industries like pharmaceuticals — robotic technologies, including AS/RS, solve these challenges. Finally, with clear value-add benefits from automation, more companies are investing in technology before prices increase or they fall behind the competition.
Q: What are AS/AR market trends?
MM: One key initiative is optimizing order fulfillment logic and capabilities in addition to control software. The objective is to funnel orders rapidly. Once consumers click “purchase” on the e-commerce site, the order should be picked and shipped out in under 15 minutes. Many companies are focused on workstation ergonomics. From a fulfillment software perspective, using past order information helps predict orders, buffer and slot inventory to keep products from sitting in the AS/ RS. For other companies, shipping orders in under 15 minutes means deploying robotic picking and palletizing solutions. Labor resources shift to quality control or retrain for more skilled tasks.
But scaling these solutions still presents a major challenge, regardless of the company’s size. Many of customers believe operations are too small to automate, so think a positive ROI will take years, particularly for large, complex systems. With increasing labor costs, that ROI equation makes more sense. OPEX prioritized making a modular, scalable and flexible system with Infinity to help make people more comfortable with the investment. We incorporated customer feedback to [enable] infinite configurations, settings, options and more.
Q: How is this system different?
MM: In traditional AS/RS, shuttles travel horizontally on a set row, and they bring inventory to
an elevator. In contrast, the Infinity iBOTs have access to all inventory in the storage grid, because they can travel in X, Y and Z coordinates. And unlike others on the market, our iBOTs can leave the storage grid to bring the inventory to detached workstations. Decoupling these stations from the AS/RS structure offers greater flexibility. For example, the iBOT could bring the tote or case to a pickand-place robot for palletizing.
Infinity is not a traditional AS/RS. It offers new dimensions of operational freedom that help users adapt to changing consumer demands or business requirements.
Q: What were the biggest technical challenges when creating the iBOTs?
MM: Traffic management and communication to the iBOTs in real-time are the two most challenging aspects of the system. The ability to plan the shortest path and optimize the traffic route around other iBOTs is a differentiator for OPEX. Our software predicts the moves that bots will make 10 steps ahead and updates routes in realtime for peak efficiency.
Q: How important is EtherCAT to achieve real-time performance?
MM: Many system elements, even at the iBOT level, require the real-time communication of EtherCAT. The traffic controller and hundreds of bots exchange packets and messages over Wi-Fi. Also, receiving data from individual system modules — such as the bots or conveyance equipment — helps us manage alerts, events and logs, then send that information to our cloud for analytics.
Using EtherCAT, the system does this in milliseconds. That is critical for Infinity’s functionality. OPEX is a member of the EtherCAT Technology Group (ETG), and we’ve developed our own EtherCAT devices to meet specific needs. Not having the determinism, flexibility and openness of EtherCAT would shackle our ability to innovate.
Q: Does Safety over EtherCAT (FSoE) help?
MM: Without FSoE, our safety architecture would be outdated and expensive. We divide Infinity’s storage grid into “multi-zone safety zones,” and the iBOTs constantly communicate location. Using the compact safety controller, we can shut down individual zones when a safety gate on the perim-
eter fence is opened. But the unaffected zones can continue running, which ensures high availability. Networking safety devices via EtherCAT helps us establish a central command center, streamlines documentation and allows customers to reconfigure or expand systems with ease. The safety controller supports modularity; you can easily add more I/O to the terminal unlike other safety PLCs that require excess hardware and redundancy additions. FSoE is key to obtaining certifications for international Infinity deployments.
Q: How does the controller optimize use of motor-driven roller conveyors?
MM: The OPEX G2P system supports automated options to convey cases and totes to the operator. The controller selected delivers a plug-and-play solution to scale our conveyance capabilities. Because of the flexibility of EtherCAT, we can easily add a 6-foot section, for example. Conveyance controls, using the same software that routes the box on Infinity, can route containers on homegrown and third-party conveyors via EtherCAT and the controller.
Q: What helped with design and launch?
MM: Regarding technology, having access to and time to learn the automation software has been extremely valuable. We can easily configure the safety systems in the automation software platform, then make changes as the application evolves.
On the business side, we started developing Infinity during the pandemic, and despite ongoing supply chain challenges, the automation provider’s customer service has delivered a positive experience. We greatly value having a direct point of contact at the company.
OPEX launched the Infinity AS/RS as a next-generation G2P system. It uses Safety over EtherCAT (FSoE), an EK1960 TwinSAFE Compact Controller, EP7402 EtherCAT Box and TwinCAT automation software from Beckhoff Automation. Courtesy: OPEX.
‘ We can easily
configure safety systems in the automation software platform, then make changes as the application evolves.
’
ANSWERS
Insightsu
AS/RS Insights
uOngoing labor shortages and the rising cost of warehouse real estate have led to increased adoption of automation technologies among logistics providers.
u To more rapidly route orders, fulfillment software can use past order information to help predict future orders, buffer and slot inventory to keep products moving.
uScalability remains a challenge, with many smaller companies feeling it could take years to achieve a positive ROI without suitably modular, flexible and scalable technologies.
Q: How does performance and reliability improve?
MM: We leverage invariance and selectivity machine learning algorithms on all the data we send to the cloud. That can include events and logs from the bots, conveyance and other equipment and performance indicators at operator stations. Behind the scenes, the system gathers data and generates reports based on those datasets to give us trend analysis. We can study and model system performance, boost reliability, increase mean time to failure and schedule maintenance. The data might also tell us to flash an update on the control panel at certain intervals and help improve operator performance. By gathering as much data as possible through fast EtherCAT communication, we learn from machines and subsystems to determine which aspects deserve a closer look. ce
Doug Schuchart, global material handling and intralogistics manager, Beckhoff Automation. Edited by David Miller, content manager, Control Engineering, CFE Media and Technology, dmiller@cfemedia.com.
OPEX: Sustainably driving warehouse automation
OPEX SUPPLIES warehouse automation and document and mail automation. The company counts 48 companies in the Fortune 100 as customers. With more than 1,600 employees across five continents, OPEX has grown since its founding in 1973 as a mail automation equipment supplier, primarily for Columbia Records. Al Stevens purchased the company in 1975, and now three generations of the Stevens family serve in leadership.
Based in Moorestown, New Jersey, OPEX maintains offices in Plano, Texas, along with Australia, England, Ireland, France, Switzerland and, most recently, Germany. The company has committed to energy-efficiency and sustainability, including powering manufacturing facilities with solar, wind and other renewable energy sources.
Robotics troubleshooting and maintenance advice
Continued from page M2
The spring-loaded switch needs to remain in the middle position, if it is depressed all the way or released, the robot cannot move.
Procedures are series of movements to different positions. They can be triggered individually or linked together. There are a variety of languages used in robotics, generally proprietary to the manufacturer. They often resemble languages such as Basic or Assembly, with JUMP and MOVE statements.
Additional high-level scripting languages also are used to build data structures or create mathematical algorithms, such as calculating paths or positions. Some languages allow parallel processing, allowing the robot to perform more than one action at a time, such as calculating movement vectors while a camera follows a moving object.
Positional data tables and programmed procedures reside in different memory areas, so one can
be changed without affecting the other. This allows positions to be changed or “touched up” by editing the table with a computer or teach pendant.
Positions are often defined in world coordinates, but the positions of individual axes of a six- axis robot can differ with the tooling of the end effector being in the same position. Positions can be taught by driving the robot to a location with a specific axis configuration and selecting “teach,” or by using a technique called “lead-by-the-nose.” This technique allows the user to manually push the axes to a specific series of positions while the axes are relaxed, describing a path. ce
– This was featured in the “Maintenance and Troubleshooting in Industrial Automation” book by Frank Lamb, the founder and owner of Automation Consulting LLC and a member of the Control Engineering editorial advisory board. Edited by Chris Vavra, web content manager, Control Engineering, CFE Media and Technology, cvavra@cfemedia.com.
Engineering innovation plays a vital role in the vitality of industrial manufacturing. You’re invited to explore the profiles on the following pages and celebrate the success stories of our participating manufacturing innovators:
• Adaptive Resources
• Applied Manufacturing Technologies
• AutomationDirect
• Beckhoff Automation LLC
• Contemporary Controls
• Digi-Key Electronics
• Dinkle Corporation, USA
• Emerson Automation Solutions
• Endress + Hauser Inc.
• Eosys
• Inductive Automation
• Motion
• Moxa Americas Inc.
• MSA Safety
• Patti Engineering
• Profibus Trade Organization
• Seeq
• SEW-Eurodrive
• Skkynet Cloud Systems
• Trihedral Engineering
Prowirl F 200 provides high measurement accuracy
Utility dependency is a global concern. As a result of world events, resource availability and climbing energy prices, sustainable operational practices are more important than ever. Tier-one consumables—such as electricity, water and gas—along with tier-two products—like steam, compressed air and heat, which are generated using tier-one utilities—power everything within the walls of industrial facilities. Optimizing resource usage is key to sustainability and profitability and instrumentation like vortex flowmeters can provide needed information and data for resource efficiency.
Despite process variable fluctuations, Endress+Hauser’s Prowirl F 200 provides high measurement accuracy for comprehensive energy management, even in compressible fluids like steam and gas. Additionally, mass flow measurement capabilities improve the accuracy of steam flow measurement compared to other products on the market. Discover key products for utility efficiency at any plant with Endress+Hauser. info.us@endress.com • Tel: +1-888-363-7377 www.us.endress.com
Endress+Hauser’s Prowirl F 200
ADVANCED
CONTROLS - Powerful but Accessible Multi-Variate Controls
Adaptive’s Process Consulting service to the Manufacturing Industry is unique. While most Process Consultants focus on Business Processes or 6-sigma or similar techniques that approach process design from a statistical perspective, Adaptive approaches Process Design from a controls perspective.
How can the process and instrumentation be designed to yield better control of the key process parameters?
The answer leads to better process design, better selection of instrumentation for the process and ultimately better control strategies. The result is to greatly reduce the variability in the Key Process parameters. Once process variability is reduced, better quality, reduced waste, higher efficiency, lower energy usage, and higher productivity can be achieved.
Process Consulting and Design Services
• High level process design evaluation
• Total Process Material Balance
• Instrumentation and Controls selection
• Control Strategy development
EMPOWER Your Continuous and Batch Processes with QUICKSTUDY ™ and QUICKBATCH ™
• Decrease Process Variability
• Decrease of out of specification product being produced
• Develop Unique Multivariate based Batch Model(s) based on changes in processing conditions.
• Drive consistent Product Quality Improvements to meet critical KPI’s
• Improves Reliability
• Capability to predict future process values
• Optimization of raw material conversions
• Process Simulation
• Process Analytics
• Process Feasibility Study
• Yield Improvement Study
• Alternative Energy Study
• Energy and Utilities Recycling Strategies
• MIMO structure allows up to 15 inputs and 2 outputs
• Remove arbitrary manual adjustments that can lead to unnecessary product waste
• Provide critical details by providing within a batch insights for the adjustments made
• Operates on multiple Microsoft ® OS Platforms
Artificial Intelligence Driven Robotic Depalletizing to Tote Challenge
Applied Manufacturing Technologies (AMT) brings artificial intelligence (AI) and machine learning (ML) vision technology to bear on warehouse material handling applications.
Warehouse automation is a rapidly rising trend, and it involves the complexity of combining materials handling equipment, sensor technology, conveyance, and software to solve these challenges at very high speeds. Many manufacturers use human operators for this function, which can be hard on the operators (ergonomics) and on the company’s bottom line. Labor challenges continue to impact the growing warehousing and e-commerce markets, so we must look to identify emerging technologies that can solve the complexity in the warehouse.
AMT is involved with leading-edge development of the next generation of material handling systems, and has tackled one of the most labor-intensive tasks in the warehouse – taking cases off a pallet and optimally placing them in a tote. This is often referred to as “decanting” or “depalletized induction.”
There are many different challenges to address in a robotic depalletizing to tote application: the case size variability, printed graphics on the packaging, pick pattern optimization, pick tool or dunnage or slip sheets, and volume of SKUs. Automating this process is far from one-size-fits-all, and along with these challenges, there are 10 key considerations for developing the optimal depalletizing solution.
Decanting in Warehousing Applications
AMT’s new robotic decanting system uses an intelligent vision system that finds the items on a pallet and determines the optimal “pick” of product to make the best use of the space in the tote. The robot picks the items off the pallet and places them in the tote, maximizing the number of objects that will fit in the tote while minimizing the number of picks, saving valuable time in this front-of-line operation.
The Warehouse of the Future
AMT helps clients achieve the warehouse of the future, which includes efficient depalletizing to tote technology with fewer errors and increased reliability, regardless of the packaging. Material handling solutions which include decanting can be complicated, but when thoughtfully designed and installed can provide a quick ROI and a reduction in risk.
There are many different challenges to address in a robotic depalletizing to tote application.
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A well-recognized name in the industrial automation market, AutomationDirect provides quality products with FREE award-winning in-house sales and technical support. AutomationDirect provides customers with quick order and delivery through an online store and toll-free number. Prices on most products are well below the industry average and a 30-day money-back guarantee is offered on nearly all items.
With close to 35,000-part listings, new products include Stahlin Enclosures, WEG rolled steel motors, Wenglor proximity sensors, Endress + Hauser capacitance level switches and Swivellink mounting systems. The company also offers the CLICK PLUS PLCs, DURApulse drives, enclosures, circuit protection, cut-to-length cable, pneumatic supplies and more.
The state-of-the-art headquarters facility near Atlanta is designed throughout for maximum performance. The majority of items are in-stock and ready for fast shipping; orders over $49 ship for FREE. Some exclusions apply.
The company provides online tutorial videos through their web store at www.automationdirect.com as well as their YouTube channel. They also provide FREE online PLC training to anyone interested in learning about industrial controls. A Customer Forum utilized by tens of thousands of automation professionals provides peer support on technical and application questions.
AutomationDirect’s customer support team has been rated top-notch by its customers and has received numerous industry accolades/awards for providing the best service and support on various products. To ensure their service and support remains superior, they continuously survey customers and have consistently outranked other suppliers.
For an in-depth look at products offered, visit: www.automationdirect.com.
Company headquarters located just north of Atlanta, GA
Orders ship quickly from our state-of-the-art warehouse
XPlanar®: Agile machines with adaptive automation
Discover the revolutionary possibilities of XPlanar ® , the planar motor system from Beckhoff. Learn how your machinery and processes can be transformed with levitating movers, flying product movement, 6 degrees of freedom and a nearly limitless array of tile paths for total flexibility in manufacturing. XPlanar gives you the freedom to intelligently adapt to constantly changing workflows and shatter all conventional thinking about automated production. Most importantly, XPlanar can help you secure an unbeatable competitive advantage and achieve the impossible.
Developed in-house and manufactured by Beckhoff, XPlanar is available for purchase today and is ready to revolutionize your application with flying motion technology. XPlanar movers float and fly freely above planar tiles arranged in customizable layouts that enable extremely flexible, precise and highly dynamic applications. For machine builders and manufacturers, this results in unprecedented flexibility and throughput with simplification in machine and plant designs. We can say this because we know. Beckhoff customers are using XPlanar in the field today to transform their operations.
The XPlanar system combines the individual arrangement of planar tiles with multi-dimensional positioning capability of the planar movers floating above them. Easy to use software tools include graphical path planning, automated jerk, pitch and yaw control, collision avoidance and 6 degrees of motion freedom. The movers enable jerk-free and contact-free motion in two dimensions at up to 2 m/s with 1 g acceleration and 50 μm positioning repeatability – completing movements without friction or wear.
XPlanar is completely integrated into the standard TwinCAT programming environment and runtime. For communication, XPlanar systems are networked via the standard EtherCAT G protocol, which itself is fully compatible with the entire 100 Mbit/s EtherCAT ecosystem.
Flying motion. Fully integrated. Available today. Break free with XPlanar.
BridgeVPN Facilitates Secure, Remote Communications for Single-Site Access
Contemporary Controls’ EIGR-VB Gigabit IP router can be configured as a wired bridge VPN server for singlesite, remote access solutions. With this configuration, users set up and maintain their own secure remote access without subscription fees and without the need for a cloud-based VPN server.
A simple VPN can exist between two end points, called a VPN tunnel, between a client and a server. One end point (client) is you at your office, and the other (server) is at the remote job site. Communication is encrypted – so only authorized devices can communicate over the VPN.
Operating in OpenVPN® server mode, the EIGR-VB supports bridge mode where up to 10 VPN clients (Windows/Linux PCs) are bridged to the router’s LAN side and assigned an IP address from the LAN subnet. This provides the same application experience as if the client devices were part of the EIGR-VB’s LAN and allows passage of multicast and broadcast messages through the VPN tunnel.
Although the EIGR-VB has many of the same features found in high-end routers, it is simpler to install and commission. A resident DHCP server on the LAN side will provide IP addresses to LAN-side clients, while a DHCP client on the wide-area network (WAN) side will accept IP address assignments from the attached network. Static addressing is accommodated as well. Configuration is via a web browser using authentication.
Setting up an OpenVPN server on your own is not trivial. It typically involves setting up a root certificate authority and generating certificates and keys for the OpenVPN server and for each client device that intends to connect to this server. However, the EIGR-VB router has a built-in webpage interface to generate certificates and keys for VPN client devices, without requiring users to download software or having to learn the complexities of setting up a VPN.
sales@ccontrols.com
630-963-7070 www.ccontrols.com
Accelerating Progress Through Innovation
Digi-Key is committed to continual innovation and a recent invention and patent exemplify the innovative spirit running throughout the company.
Last year, Digi-Key was awarded a U.S. patent for a tray designed to transport and store electronic components. The tray was invented by Digi-Key engineers Shane Heinle and Reid Landsrud who set out to create a safer and more efficient way of transporting broken pack integrated circuits. The trays are a quarter of the size of the industry standard JEDEC trays allowing for a smaller packaging and shipping footprint for smaller quantity items, as well as a reduced environmental impact.
After inventing the tray, Digi-Key worked with fellow Minnesota companies Holland Molds of Wadena, Minn., RTP Company of Winona, Minn., and CCI of New Hope, Minn. to assist in commercial production of the tray.
“To me, everyone at Digi-Key is an engineer, and we have to make things work every single day,” said Shane Heinle, senior supervisor, ESD program control for DigiKey. “This is truly a local product from idea to production that is having global implications for our customer base.”
“It’s amazing the amount of packaging we save by using this smaller tray which offers the exact same benefits as the standard larger tray, just right-sized for the number of components we ship often,” said Reid Landsrud, supervisor, resident maintenance technician for Digi-Key. “We are able to send components in a smaller shipping box, with a smaller moisture barrier bag, a smaller amount of desiccant and a lower shipping cost; decreasing shipping and packaging prices and lessening the environmental impact.”
Innovative ideas are a constant at Digi-Key, from frictionless interactions to next-generation solutions. All indications are that 2023 is shaping up to be a good year of new product development for our engineering customers as well. We look forward to the continued innovation of our customers and we work together to accelerate progress.
For more information, please visit the Digi-Key website.
DINKLE Push-In Lever-Up Terminal Blocks
and Connectors Provide Options for Designers
Established in 1983, DINKLE is a global terminal block manufacturer and operates its businesses in over 40 countries. DINKLE provides highly reliable and durable products globally in the industrial sectors such as Factory Automation, Process Automation, New Energy, Equipment Manufacturing and many more. The products have various safety approvals including UL, CUL, CSA, VDE and GB, and the material are compliant with RoHS and REACH environment standards.
DINKLE aims to support global customers with the professional customization solution and value-added service. In the 40th Anniversary, DINKLE has launched a new family of Push-in Lever-Up terminal blocks and connectors, which provide superior performance and usability to OEMs and electronics designers. By focusing on the studies of the handle operating force, rebound force, operating space, etc., the exclusive patented P-LUP structure technology with lower space requirements and more convenient use has been developed, which is comfortable and labor-saving to pull the operating lever.
0256/0257 series Product Category: PCB Connector Pitch: 3.50/3.81/5.00/5.08mm
0274/0275 series Product Category: PCB Type Pitch: 5.00/7.50/10.00/14.50mm
To check P-LUP product: https://bit.ly/3nEt9WA
Watch the youtube video: www.youtube.com/ watch?v=BCnTW5wk7vA
Dinkle P-LUP terminal blocks are easy to use, and they readily accept stranded wire, solid wire, or ferrules while providing robust connectivity and labor savings compared with using traditional screw terminals. The ergonomic design and easy one-hand use were prime considerations in the design of Dinkle P-LUP terminal blocks. Terminal blocks in the P-LUP family are available in a range of sizes and ampacities, in arrangements for soldering into PCB through-holes or for connecting to standard on-board pluggable sockets. Due to compatibility with industrial standards and a suitable form factor and wire connection orientation, PCB designers can seamlessly upgrade from screw to P-LUP lever connection technology without affecting existing PCB designs.
Productivity and Profitability are at the Edge
Rich data that can immediately inform industrial users about the health of machinery, the productivity of systems, the impending need for maintenance and much more is available from every corner of every plant – but industry still struggles with how to collect, analyze and communicate that data fast and affordably.
That’s why Gartner says, “By 2025, 75% of enterprise-generated data will be created and processed at the edge — outside a traditional data center or cloud.”
Why is your future at the edge? Because edge solutions let you start where you are today, whether you need a single, low-footprint edge computing system or full-scale plant analysis and supervision, and cost-effectively solve real-world problems one at a time.
Emerson makes edge technology easy. Emerson’s PACSystems™ Edge solutions are made up of natively integrated hardware and software systems that get vital data into the hands of the exact people who can use it in language they understand. Make fast, informed decisions from the machine level to the enterprise level. Connect highly disparate machines and systems, unlock isolated machines, assess machine health, improve productivity and overall equipment effectiveness, enhance energy efficiency, eliminate downtime, reduce costs, simplify operations for operators at every level, overcome remote operation limitations – PACSystems Edge solutions do it all, one easy step at a time.
How much could you improve performance if you could intuitively connect, collect and analyze data across your entire organization to turn it into actionable insight? And start today.
A Double Shot of Digital Transformation
Jack Daniel’s, the famous Tennessee whiskey brand, operates a large bottling plant in Lynchburg, Tennessee. The plant is responsible for bottling and packaging the company’s various whiskey brands, including Jack Daniel’s Old No. 7 and Gentleman Jack. To manage production and quality, the plant relies heavily on TrakSYS, their sophisticated manufacturing execution system (MES).
When Jack Daniel’s aimed to enhance tank level visibility, they collaborated with EOSYS to upgrade their MES. Though seemingly straight forward, engagement with multiple stakeholders revealed additional complexities and opportunities.
The statement of work called for a tank level dashboard and all necessary systems integration components to capture data and provide real-time visibility. Given the complexity of tanks and piping leading to bottling lines, Jack Daniel’s and EOSYS employed an agile approach to manage the project.
Using scrum (a brand of agile) enabled the team to swiftly identify and address issues without waiting for extensive development cycles. They promptly delivered a minimum viable product for the cross-functional Jack Daniel’s team to evaluate and provide feedback. Rapid progress was made, with enhancements deployed multiple times per day. The agile process encouraged the cross-functional team to innovate and identify ways to make better decisions using the new information, such as optimizing changeover planning.
Embracing an agile approach facilitated innovation and allowed the team to focus on delivering the most value, even for items not initially in the scope. This resulted in a more valuable project at a lower cost without the need for change orders.
Jennifer Crabtree, a representative from Jack Daniel’s, shared her experience, saying, “The collaboration with EOSYS and the agile methodology they used allowed flexibility and most importantly adaptability to our current situation which allowed different departments’ stakeholders to collaborate regarding the best solution that benefited all departments and the bottom line.”
By adopting agile principles and digital transformation technologies, companies like Jack Daniel’s can stay nimble and responsive to the ever-changing demands of their industry.
Ignition by Inductive Automation Elevates Your Enterprise at Every Level
Ignition by Inductive Automation ® is an industrial application platform with tools for building HMI, SCADA, IIoT, MES, and digital transformation solutions. Ignition provides one platform for total system integration, and you can run it wherever your data and devices are. With all your people, processes, and programs connected, your enterprise will be free to achieve true digital transformation and endless innovation.
And More:
On The Plant Floor
The standard Ignition platform has a full range of drivers and tools to connect to any device and develop applications for SCADA and so much more.
At The Edge
Ignition Edge runs on embedded devices and offers edge computing and data collection from remote sites.
In The Cloud
Ignition Cloud Edition leverages the power of AWS and Azure, allowing you to easily tap into additional services and flexibility.
• Build Mobile-Responsive Applications with the Ignition Perspective Module inductiveautomation.com/ignition/modules/perspective
• Bring Innovation Home with Ignition Maker Edition inductiveautomation.com/ignition/maker-edition
• Free Project Resources at the Ignition Exchange inductiveautomation.com/exchange
• Free Learning at Inductive University inductiveuniversity.com
• Integrator Program inductiveautomation.com/integrators/join
• International Distributors inductiveautomation.com/distributors
• Educational Engagement Program inductiveautomation.com/educational-engagement
Inductive Automation Celebrates 20 Years of Elevating Industrial Automation. Visit inductiveautomation.com
Bin-Picking: A New Automated Solution for an Old Manual Process
By Brody Diggins and Logan Martin, Motion Ai
One significant element of robotics in the industrial industry is efficiency. Everything revolves around uptime and the revenue stream that comes in through the products you create. Bin picking is one part that has held factories back for decades; its intricacy has impeded robots from successfully picking the correct item out of a bin of various parts. In recent years, bin-picking automation has made great strides: the process is faster and saves money in the long run with vision software and robotics.
How Our Bin-Picking
Automation Works - Before, intricate and small products were nearly impossible to sort correctly and were too expensive to attempt sorting when it could go wrong. Now, AI-driven bin picking has solved the previous sorting difficulties. It starts with a checklist of what must happen for accurate sorting. The list guides the robot on what to do and when, ensuring it only does the same action once. In this checklist, the robot precisely plans the path to search the box. A collision-avoidance feature allows the specific object to be identified, picked from the bin, and sorted correctly.
Operations - Before running these robots, the operator must learn the robotic programming for the specific task, work cell process design and correct camera setup, and complete AI training in parallel to these other factors.
The AI bin-picking solution is immune to different conditions that could impact original bin-picking systems. The camera set is not inhibited by ambient lighting.
How Bin-Sorting Solutions Improve Automation - Besides saving costs, automated bin-picking solutions will make your factory run smoother and faster than ever. The accuracy is unbeatable, few or no mistakes are made on the factory floor, and bins are sorted exponentially.
Although bin-picking solutions used to be costly, they are more accessible now that they have been simplified and are ready to be used in the factory daily.
Ready to automate your bin-picking process? Contact Motion Ai and speak to a rep today.
Image courtesy of Motion Ai.
Industrial
Network Security and the New IEC 62443-4-2 Standard
Although cybersecurity has been a hot topic amongst IT teams for years, sufficient attention has only been recently given to combating cyber threats in industrial environments. In 2018, the ISA/IEC released a new networking hardware standard (ISA/IEC 62443-4-2) to ensure that industrial networking devices, such as switches, routers and wireless access points, had security features that would allow OT professionals to adequately configure security on their networks. Moxa has engineered innovative networking technologies to assist organizations to capture, transmit, and ultimately transform data into meaningful insights, securely and efficiently.
EDS-G4000 Managed Ethernet Switches for Device Security
To enhance component-level security, Moxa has introduced one of the world’s first IEC 62443-4-2 certified Ethernet switches, the EDS-4000/G4000 Series. With easy management and maintenance, and up to 2.5 GbE bandwidth for highly efficient Ethernet networks, this switch was custom designed for industrial applications. These next generation switches include 68 models that will help build reliable, futureproof industrial networks. Visit https://pages.moxa.com/us-eds-4000-g4000.html to learn more.
EDR-G9010 for Network Segmentation & Firewalls
The EDR-G9010 Series’ industrial secure router uses firewall policy rules to filter network traffic between trusted zones. It also supports Network Address Translation (NAT) for segmenting the network, while providing basic protection from unauthorized access by outside hosts. To help protect your OT assets from cyberattacks, the EDR-G9010 Series supports Deep Packet Inspection (DPI) to data level inspection of network packets for various OT-specific protocols.
Network Visibility with MxView
Moxa’s MXview network management software is designed for simplified configuration, monitoring, and troubleshooting industrial networks. MXview provides an integrated management platform that can discover networking devices and SNMP/IP devices installed on multiple subnets. All selected network components can be managed via a web browser from both local and remote sites—anytime and anywhere. There is even a mobile app to keep you connected when out of the office. Find out more about Moxa’s cybersecurity solutions at https://pages.moxa.com/us-network-security.html .
714.528.6777 • info.us@moxa.com www.moxa.com
MSA Safety: Creating Next Generation Safety Technology
MSA Safety believes the future of many industries lie in connected detection platforms and their abilities to provide actionable and meaningful data to positively impact process safety. Adopting new technology that helps to simplify safety procedures and connect managers to their employees and equipment in hazardous environments is becoming easier through digital transformation. The power of data analytics is quickly becoming a game-changer in industrial facilities, largely because of advances in gas detection technology that are helping companies gather and use data to better protect people, places, and the planet.
“MSA’s Connected Work Platform brings workers, worksites and workflows together to help make safety simpler,” said Gustavo Lopez, MSA Safety’s Vice President of Connected Services & General Manager of Industrial Products.
“We’re empowering managers to use the platform as a solution to develop adaptable and proactive safety plans by leveraging our worldclass sensor technology and cloud-based solutions to enhance safety and productivity.”
The company’s Ultima® X5000 is at the forefront of fixed gas detection by incorporating Bluetooth ® technology that allows users to securely access the instrument using MSA’s X/S Connect app. The app allows users to easily configure the detector’s settings for faster commissioning, checks the status of the last successful calibration, and can provide real-time alerts from outside the hazardous area.
Established in 1914, MSA Safety is the global leader in the development, manufacture, and supply of safety products and software that help protect people and facility infrastructures.
Many MSA products integrate a combination of electronics, software, mechanical systems, and advanced materials to protect users against hazardous or life-threatening situations. These products are used by workers around the world in markets including the oil, gas and petrochemical industry, industrial manufacturing applications, HVACR, utilities, and the military.
Headquartered near Pittsburgh, PA, MSA has approximately 5,000 employees worldwide.
The MSA Ultima X5000 gas detector seamlessly integrates with the X/S Connect app.
Bridging the Gap Between Analytics and Manufacturing
Leaders in Digital Transformations
Patti Engineering stands out as an integrator that possesses expertise in both manufacturing and digitalization, making them uniquely qualified to assist with programming automation and performing data analytics. They have a profound understanding of manufacturing operations and the challenges faced by manufacturers, and they use that knowledge to help clients successfully undergo digital transformations. Bridging the gap between Operations Technology (OT) and Information Technology (IT), Patti Engineering delivers the highest value to their clients.
Closing the Loop of Digitalization
Keeping up with the latest advancements, digitalization is not a mere checkbox, but an ever evolving system that demands regular maintenance. Industry 4.0 and
digitalization are driven on data, and Patti Engineering has found that by closing the data loop, the data found at each step can be used as the starting point for the next.
Patti Engineering is well-equipped to assist throughout this entire process. From collecting raw data from physical systems and contextualizing it using edge/cloud devices, to calibrating digital twins by incorporating real data into simulations, Patti Engineering can facilitate testing new scenarios and updates using the digital twin and analyzing the results to enable manufacturers to identify necessary changes to the physical system, starting the cycle anew.
Customizing Solutions to Fit Client Needs
Patti Engineering offers a wide range of services to increase efficiency and optimize operations for their clients through advanced technologies and innovative solutions. They are dedicated to working with their clients to understand their processes, challenges, and requirements in order to provide the right solution. They leverage their expertise in control systems integration, robotics, and asset tracking to streamline production and use Industry 4.0 solutions and digital tools such as AI, IoT devices, simulations, and edge/cloud to improve business profitability and agility.
With offices in Michigan, Indiana, and Texas, Patti Engineering can aid customers nationwide.
Sam Hoff, Founder and CEO
The digitalization data loop
About PI North America
PI North America is a non-profit, member-supported organization for industrial networking, specifically PROFIBUS, PROFINET, IO-Link, and omlox. It is dedicated to supporting industry in achieving beneficial results using these technologies. PI North America also assists device manufacturers in the development and marketing of PROFIBUS, PROFINET, IO-Link, and omlox products. Members of PI North America include vendors of hardware, software, and systems as well as end-users and operators, scientific institutes, universities, distributors, and system integrators.
PROFIBUS
To date, more than 68,000,000 PROFIBUS devices have been installed worldwide. PROFIBUS is the global standard when it comes to fieldbuses in industrial automation. With a majority share of the fieldbus market, PROFIBUS has grown to become the unequivocal leader in this segment.
PROFINET
The total number of PROFINET devices installed exceeds 65,000,000. PROFINET is an all-encompassing Industrial Ethernet protocol built for advanced manufacturing. It is the standard for industrial networking in automation. It connects devices, systems, and cells, facilitating faster, safer, less costly, and higher quality manufacturing. It easily integrates existing systems and equipment while bringing the richness of Ethernet down to the factory floor.
IO-Link
At 36,000,000 nodes, IO-Link has become the worldwide leader for connecting smart sensors and actuators for automation. IO-Link is a serial, bi-directional point-to-point connection for signal transmission and power supply under any network, fieldbus, or backplane bus. The low-cost interface enables insight into the ‘last meter’ of an industrial network.
omlox
omlox is an open and interoperable standard for a real-time location system (RTLS) in industry. The focus of omlox is to define open interfaces for an interoperable location tracking system. The hardware component is based on ultra-wideband (UWB) technology due to its high accuracy and robustness. In addition to UWB, the software component enables interoperability and flexibility across different complementary zones such as RFID, 5G, Bluetooth, Wi-Fi, and GPS.
A global leader in advanced analytics for process manufacturing
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 selfservice, 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.”
info@seeq.com • 206-801-9339 www.seeq.com
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.
CliCk or Scan QR code to request a DEMO.
Dustin Johnson Chief Technology Officer at Seeq
Technology Updates and Automation Expertise from SEW-EURODRIVE
SEW-EURODRIVE — Much More Than Gearmotors
Our team of (MAXOLUTIONS) 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 work together seamlessly — because we designed them that way!
Complete Drive Maintenance and Management
SEW-EURODRIVE now offers a full complement of drive maintenance and management services. Our CDM ® Maintenance Management service provides a 24/7 online portal as well as a complete overview of your drive components, the condition of your units, drive usage, and service details. Plus, our new onsite Pick-Up Box Service will free up your maintenance team for other tasks. Just place your drives that need repair in the supplied box and we’ll handle the pick-up and return of your units.
MOVIGEAR® and MOVI-C® for Decentralized Installations
MOVIGEAR is the mechatronic drive system that combines the gear unit, IE4 motor, and electronics in one compact unit. Updates include fully integrated Ethernet/IP communications and digital motor integration. This advanced single-cable technology carries power, feedback information, and control signals along a single hybrid cable between decentralized devices. MOVI-C modular automation system is a one-software, one-hardware, automation platform that combines fully integrated components, control electronics and software.
About SEW-EURODRIVE
Engineering excellence and customer responsiveness distinguish SEW-EURODRIVE, a leading manufacturer of integrated power transmission and motion control systems. SEW-EURODRIVE sets the global standard for high performance and rugged reliability in the toughest operating conditions. With global headquarters in Germany, its U.S. operations include a state-of-the-art manufacturing center, five regional assembly plants, more than 63 technical sales offices and hundreds of distributors and support specialists. This enables SEW-EURODRIVE to provide local manufacturing, service and support, coast-to-coast and around the world.
Cogent DataHub ® technology from Skkynet lets you network OPC DA data using only local OPC connections, and pass the data across the network over TCP, with optional SSL if needed. A DataHub tunnel/mirror avoids DCOM and solves the Microsoft KB5004442 security patch problem.
Microsoft took an important step this spring towards keeping industrial systems secure. They made their KB5004442 security patch for DCOM mandatory. This affects all systems that network OPC DA, one of the most widely used industrial protocols in the world. Now all OPC DA systems that use DCOM across a network must use the highest security settings. Any networked connections with lower security settings will fail.
To solve this problem, DataHub tunnel/mirroring makes only local connections to both OPC DA servers and clients. It passes their data across the network over TCP, using SSL if required. Both OPC DA server and client stay connected if the connection goes down, and the client is informed of the break. This approach completely eliminates the need for DCOM.
For moving data beyond the plant network, DataHub tunnel/mirror technology offers a more secure connection than DCOM. You can configure it to make only outbound connections from the OPC server side. This keeps all inbound firewall ports closed, while still allowing the data to flow one way or both ways.
To connect OT to IT for remote access, DataHub tunnel/mirror technology supports network isolation through a DMZ. By installing a third DataHub instance on the DMZ, each side can make outbound connections through firewalls, and still maintain one-way or two-way data flow.
Whatever your application, there’s no need to view Microsoft’s move to secure DCOM as a problem. DataHub tunnel/mirror technology offers solutions at any level that are more flexible and more secure than DCOM.
Find out more.
sales@skkynet.com
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VTScada Receives IEC 62443 - ML 2 Cybersecurity Certification for its Secure Development Lifecycle Process
Some of the largest automation systems in the world rely on VTScada software to ensure system uptime. For this reason, the VTScada development team has always taken great care to provide advanced cyber security features and follow software development best practices. Now, after rigorous evaluation by exida, VTScada has again risen to the high standards required to help keep mission critical infrastructure safe.
VTScada’s Development Environment is now certified to be compliant with IEC 62443 Security for Industrial Automation and Control Systems - Part 4-1: Secure Product Development Lifecycle Requirements for Maturity Level 2.
This standard defines secure development life cycle (SDL) requirements for products used in industrial automation and control systems. This includes security requirement definitions, secure design, secure implementation verification and validation, defect management, patch management, and product end-of-life.
These can be applied to new or existing processes for developing, maintaining, and retiring hardware, software, or firmware.
exida is a world leader in product certification specializing in automation system safety, alarm management, cybersecurity, and availability.
See the certificate here:
To learn more about VTScada’s resiliency features visit www.vtscada.com.
Toll-free: 1-800-463-2783 (North America) Worldwide: 1-902-835-1575 info@trihedral • www.vtscada.com
Who should enter?
If you’re a system integrator with demonstrable industry success, Control Engineering and Plant Engineering urge you to enter the 2024 System Integrator of the Year competition. Past System Integrator of the Year winners—Class of 2023, Class of 2022, and Class of 2021—are not eligible to enter the 2024 System Integrator of the Year program.
What’s in it for the winners?
The chosen System Integrator of the Year winners will receive worldwide recognition from Control Engineering and Plant Engineering. The winners also will be featured as the cover story of the Global System Integrator Report, distributed in December 2023.
How will the competition be judged?
Control Engineering and Plant Engineering’s panel of judges will conscientiously evaluate all entries. Three general criteria will be considered for the selection of the System Integrator of the Year:
• Business skills
• Technical competence
• Customer satisfaction
Innovations
Electro-hydraulic actuators with quarter-turn design, ESD inputs
Rotork has introduced a compact, quarter-turn design to its Skilmatic SI range of self-contained electro-hydraulic actuators. The new actuator uses a rack and pinion drive for a torque output of up to 1,000 Nm (737 lbf.ft). The SI range of actuators combine the simplicity of electrical operation with the precision of hydraulic control and the reliability of mechanical spring-return fail-safe action. Typical applications for Skilmatic SI actuators include functional safety-related Emergency Shutdown (ESD) inputs and Remotely Operated Shutoff Valve (ROSoV) duties. Robustly constructed for challenging environments, SI actuators deliver a highly reliable means of safety valve positioning and intelligent management. Rotork, www.rotork.com
Precision metering gear pump for additives, sealants and chemicals
Circor International announced its Zenith C9000 Series precision metering gear pump, ideal for use in hydrogen fuel cell MEA gasketing sealants and adhesive applications. The metering pumps deliver accurate and repeatable flow of metering additives, sealants or chemicals in a compact and efficient design. The pumps offer near constant flow without the need for expensive flow meters and control systems, featuring an extended mean time between failure (MTBF). The pumps are available with an innovative magnetic drive (mag-drive) sealing option, which eliminates shaft leakage of fluids, improving plant safety while reducing VOC emissions and seal failures.
Circor International, www.circor.com
Plug-in motor controller for integration into devices
Nanotec introduced a new controller specifically for integration into devices: the NP5 plug-in motor controller, which is suitable for brushless DC motors as well as for stepper motors. A PCI Express connector allows for integration into a customer-specific board — thus offering a compact and low-cost product that reduces the wiring effort, particularly for multi-axis applications. Nanotec Electronic, www.us.nanotec.com
Spring-loaded position sensors check part dimensions
NewTek spring-loaded LVDTs provide precise dimensional measurement of high-volume molded automotive parts in plastic mold testing. Different interior, exterior and mechanical automotive parts, such as bumpers, heating components and door handles are manufactured through an injection molding process. To ensure product consistency, quality and adherence to federal and state standards, the molded parts are tested for defects. Newtek, www.newteksensors.com
Capacitance level switches for pellets, water-based conductive liquids
Endress+Hauser’s Nivector FTI26 and Liquipoint FTW23 series point level capacitance switches are contact sensors that detect presence by evaluating differences in dielectric values. They are useful for detecting the level of solids, such as plastic pellets or water-based conductive liquids. The Nivector FTI26 series, available in rugged polycarbonate or stainless-steel housings, detects powders or fine-grained bulk solids in silos, hoppers and bins. Stainless-steel versions are FDA compliant and marked with the 3-A symbol for food industry hygienic applications. Select models are CSA approved for hazardous locations. The Liquipoint FTW23 series, developed and built for the food industry, detects water-based liquids in storage tanks, mixing vessels and pipes. Endress+Hauser, www.endress.com
NEMA 4-certified cabinet coolers, IP66 rating
Exair products are engineered to improve efficiency while increasing facility safety in the process. This ongoing focus on standards and personnel safety has earned Exair NEMA 4 Cabinet Cooler Systems an upgraded CE certification under their latest safety directives. The NEMA 4 (IP66) Cabinet Coolers are constructed from durable aluminum and designed to cool dusttight, oil-tight, splash-resistant indoor/outdoor enclosures. This cooling method can be installed in minutes through a standard electrical knockout. NEMA 4 Cabinet Coolers provide a lowcost alternative to other cooling methods.
Exair, www.exair.com
DIN-rail mounted DC-DC power converters
Industrial analytics software for detecting process and machine anomalies
Falkonry Insight is an industrial analytics application that can ingest and process huge volumes of time series data to reveal process and machine anomalies. It allows users to review patterns that deviate from expected behavior, compare signals, diagnose issues and generate reports. This overview of the operating environment allows prioritization of issues that will have the most impact on uptime, quality and yield. The patented AI engine is automated and does not require any setup and maintenance. Since the AI can process available data, the application present users with more opportunities for finding concerning behaviors. Falkonry, www.falkonry.com
Antaira launched two DIN-rail mounted DC-DC converters capable of boosting the 9-36VDC input power typical of control cabinets to a maximum adjustable output of 53VDC and up to 480 watts (DTD-480-0953-T) or 360 watts (DTD-360-0953-T). Rugged and compact, the new DTD power converters are shielded from industrial environments within an IP30 metal housing can withstand a temperature range of -40°C to 75°C, along with exposure to shock and vibration. With an eye on minimizing downtime, the converters safeguard against poor power quality with protection against damaging short circuits, overload, reverse polarity and under voltage. A built-in SVR allows adjustment of output voltage to address specific device needs. Antaira, www.antaira.com
G3 universal input rack PDU for many rack layouts, power needs
Features of the Eaton G3 UPDU include: Supports 5 kVA single-phase through 23 kVA three-phase power and can be paired with any one of 12 detachable input cords with 12 plugs; C39 outlets for C14 and C20 plugs, adding flexibility to deployments and simplifying the PDU selection process; meets industry standards used all over the world, enabling customers to source one PDU chassis globally and pair it with input power cables rated for voltage requirements at each destination. Toolless mounting buttons offer multiple mounting options.
Eaton, www.eaton.com
Mini PCI Express multiport serial board, faster system integration
Moxa’s new CP-102N Mini PCI Express multiport serial board fulfills the need for customized expansion of industrial automation systems, and enables faster time to market for OEMs and integrators with minimal increase in power consumption or system footprint. Designed for industrial automation systems and industrial PC manufacturers, the serial board is compatible with any Mini PCI Express slot, and requires only a 3.3 VDC power supply, allowing it to work with host computers ranging from DIN-rail PCs to standard-sized PCs. It includes isolated and non-Isolated RS232/422/485 communication cards for various applications.
Moxa, www.moxa.com
See more New Products for Engineers www.controleng.com/NPE
Functional safety dual input smart HART DIN-styled temperature transmitter has IS option
Part of Moore Industries’ FS Functional Safety Series, the SIL 2 and SIL 3 capable STZ Functional Safety Dual Input Smart HART Temperature Transmitters for a SIS (safety instrumented system) configures quickly and easily to accept a single or dual input from a wide array of sensors and analog devices located in hazardous and non-hazardous areas, with 14 RTD types, 9 thermocouple types, resistance and potentiometer devices and direct millivolt sources. Moore Industries, http://www.miinet.com
General-purpose photoelectric (PE) sensor family
Idec Corp. introduces the SA2E general-purpose photoelectric (PE) sensor family, in five major models, each which improve on or replace proven SA1E products. A new ASIC provides a significantly improved price/performance ratio, while delivering better response times and more capable detection. The sensors are offered in five major variations: T: Through-beam, for detecting objects passing between emitter/receiver pairs; P: Polarized retro-reflective, for detecting objects passing between the receiver and a reflector, in difficult lighting conditions; D: Diffused-reflective, for detecting targets by the light reflected from the target; B: Background suppression reflective, for improved and reliable detection of a wide variety of targets by the light reflected by the target. Idec Corp., https://lp.idec.com/SA2E-Miniature-US.html
MEDIA SHOWCASE FOR ENGINEERS
Back to Basics
EDGE COMPUTING TECHNOLOGY
5 edge technology trends, insights
Edge technology and digital transformation trends within the industrial sector that could impact manufacturing.
The manufacturing sector is being transformed through a new world of digital factories. Ubiquitous sensing and connectivity at the edge are yielding data that opens the door to new depths of operational insight. Simultaneously, key technology trends such as modular system design, localized decision making and ubiquitous sensing, are key enablers of digitization, allowing manufacturers to reduce energy consumption while driving critical business goals. As companies move toward a sustainable industrial future, there are five key technology trends emerge that will drive new investment in edge technology hardware and software.
1. Automation. Across the industrial landscape more and more automation is being deployed, via robotics and configurable systems with the purpose of increasing productivity, quality and to address workforce shortages. More automation equipment means that more hardware and software technology is being deployed. One example is seamless configurability and connectivity from the edge on the factory floor to the cloud. Unique software-configurable analogue front ends, paired with digital connectivity technologies for direct IP addressability, are creating nimble connectivity networks for real-time automation control. This enables the concept of agile manufacturing which brings to life quick configurability and drives overall asset utilizations.
higher processing power and retains low power consumption to enable devices run via low-power supplies, such as batteries or single-pair power over Ethernet.
3. Digitization, connected enterprise
network identify failure output.
This requires deployment of more intelligence to enable local decisions. Industrial automation machinery has the intelligence to dynamically respond to real-time operating conditions, based on the health and status of a network of sensors located across the factory floor. As well as enabling local optimization, this network of sensors is providing insights to centralized artificial intelligence (AI) units that can identify manufacturing bottlenecks and points of failure and optimize manufacture cell output. This is driving the need for AI/ ML and higher capability processing technologies at central control levels to process the data feeds quickly.
4. Next-generation industrial technology. This addresses the new capabilities that are coming on stream to enable machine health monitoring. For condition monitoring, you are ensuring the asset is operating in its zone of peak performance or efficiency, helping to maximize the life of assets.
2. Electrification. Electrification of the factory and the use of mixed energy sources such as renewables to reduce dependence on fossil fuels is driving a three-fold increase in energy demand. The answer is to use the energy we have more efficiently. For example, retrofitting boilers and furnaces to move from fossil fuels to high temperature heat exchangers. Each time a change is made new control and automation equipment is needed up the chain and better monitoring and control within the boiler is required to operate in its zone of efficiency. Each new device will be fitted with more intelligent sensors, processing platforms and optimized machine learning (ML) algorithms to enable real time monitoring, ensuring operation in its zone of efficiency. This drives demand for
5. Greater cybersecurity With the connected and interconnected factory automation networks comes the need for security. This drives features like secure boot, secure software update, authentication, and root of trust. The root of trust is a set of related security functions that control the cryptographic process in the devices as a largely separate computing unit. Connected factory devices require some security to prevent them being identified as a vulnerability in system networks. ce
Fiona Treacy is senior director industrial automation at Analog Devices. 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.
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