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input #1 at www.controleng.com/information
Make the Invisible Visible
A showcase for the world’s most advanced 2D and 3D HMI/SCADA
technology, ICONICS recently concluded its Worldwide Customer Summit
in Providence, Rhode Island. Groundbreaking technology demonstrations
included its Holographic Machine Interface (HMI), enabling users to make
the invisible visible and experience a new dimension in augmented reality
for manufacturing and industrial automation. 2018
Watch Our Highlight Reel Video
 www.iconics.com/wwcs2017/highlights FINALISTS

© 2017 ICONICS, Inc. All rights reserved.

input #2 at www.controleng.com/information
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 Vol. 64
Number 12

DECEMBER 2017

18
17 | ANSWERS
21
COVER IMAGE, ABOVE:
18 | Virtualized manufacturing, simulation
Immersive 3-D virtual reality opportunities
technology simulates robotic weld-
ing processes for more efficient 21 | 3-D robotic welding simulation benefits
design and concept review prior to
build. Courtesy: Robotic Industries
Association (RIA)/Genesis
23 | Customers need process control building
Systems Group LLC blocks and standardization
COVER IMAGE, RIGHT: Virtual manufacturing began as a way to design and test tools
and has grown to become a powerhouse for supporting production processes and product 25 | One cable automation combines
development. Digital models capture information about the product for rapid prototyping
and eventually mass production on the factory floor. Courtesy: L&T Technology Services communication and power
INSIDE PROCESS
05 | INSIGHTS M1 | Picking the right discrete sensor
06 | 2017 Programmable Controllers for a machine application
Software & Hardware study: M4 | Wireless as a means to overall
Five industrial controller findings equipment efficiency
08 | Companies need to address collaborative
robot issues 33 | INNOVATIONS
10 | Using a virtualization approach can save NEW PRODUCTS
time, money, and resolve backup and
recovery issues 34 | Apps control functions of digital
pneumatics; Metal-sealed ball valves;
11 | Five technology trends for 2018 Fiber optic microswitch series; Surge
12 | Using energy management software protective device
to lower overall costs
35 | Embedded computer for DAQ appli-
13 | Collect, optimize data cations; Temperature transmitter with
intrinsically safe sensor connections
NEWS
14 | Electronics manufacturing drives 36 | Splicing connectors for grounding
industrial robotics market growth; and bonding; Pressure transmit-
Industrial Internet groups announce ter with low-power voltage output;
digital solar plant testbed; Online Industrial UPS system
articles BACK TO BASICS
15 | Think Again: Looking ahead 40 | 3 cybersecurity changes for manufacturers
CONTROL ENGINEERING (ISSN 0010-8049, Vol. 64, No. 12, GST #123397457) is published 12x per year, Monthly by CFE Media, LLC, 3010 Highland Parkway, Suite #325 Downers Grove, IL 60515. Jim Langhenry,
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www.controleng.com CONTROL ENGINEERING December 2017 • 3

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 INSIGHTS

TECHNOLOGY UPDATE
RESEARCH Using energy management
Five industrial 12 software to lower costs
6 controller findings Energy management software is designed to
Respondents to Programmable Controllers measure costs and deliver quantifiable results for
Software & Hardware study identified five key find- companies, from 5% to 25% annual energy cost
ings regarding what end users expect and how savings. It also can be integrated with the cloud to
they purchase or specify industrial controller soft- lower energy costs and provide more immediate,
ware and hardware. hands-on data for users.

M More
INSIGHTS TECHNOLOGY UPDATE

More research details, other topics 13 Collect, optimize data

Use automation to
www.controleng.com/ce-research
collect pertinent oper-
ations data in the right
CONTROL ENGINEERING EUROPE format for worthwhile
Companies need to address
8 collaborative robot issues
outcomes. See three
data structure tips.

Collaborative robots are a hot topic in manu-

facturing and their use will grow as companies
NEWS
implement Industrie 4.0, but companies need
to consider safety issues and how collaborative Electronics manufacturing
robots compliment the workforce. driving industrial robotics
market growth; Industrial
TECHNOLOGY UPDATE 14 Internet groups announce
Overcoming compatibility
10 issues with virtualization
digital solar plant testbed;
Online articles
Using a virtualization approach can save time,
money, and resolve backup and recovery issues.
THINK AGAIN
TECHNOLOGY UPDATE Top 10 Control Engineering
11 Five technology 15 topics for 2018
trends for 2018 Hottest 2018 topics in automation, controls, and
With advancements in automation, industries instrumentation are here, but don’t take my word
need to stay on top of the challenges ahead. for it; help write future history.

M More
INSIGHTS Weekly Top 5 articles recap the most-read
articles at www.controleng.com posted
Need a topic-based, answer-oriented
Control Engineering newsletter?
during the prior two months.
www.controleng.com/enewsletters

www.controleng.com CONTROL ENGINEERING December 2017 • 5

 Estimated expenditures
INSIGHTS for MV drives
RESEARCH Don't $250,000
know or less

23%
2017 CONTROLLERS STUDY 31%

Five industrial
controller findings 26%
20%

T
he Control Engineering 2017 Pro- 4. Cybersecurity: Seventy-six per-
grammable Controller Software cent of respondents reported that their $500,001 $250,001 to
& Hardware Study unveiled five companies restrict access to controllers or more $500,000
key findings regarding what in an effort to protect these devices;
end users expect and how they purchase 55% have increased password protec- End users estimate an average
or specify industrial controller software tion procedures. expenditure of $509,000 for medi-
and hardware: 5. Looking ahead: Eight in 10 end
um-voltage (MV) drive products
1. Usage of industrial controller users expect to buy industrial control-
software, hardware: Programmable con- ler software or hardware in the next 12 over the past 12 months. Source:
troller software or hardware is most com- months; end users expect to use/pur- Control Engineering 2017 Motor
monly used for discrete and continuous chase an average of 9 industrial con- Drives Study
manufacturing (22%), continuous manu- trollers during this time frame. ce
facturing (22%), or continuous and batch

66%
manufacturing purposes (19%). View additional findings at www.contro-
2. Justifications: The top situations leng.com/2017ControllersReport. of end users have had
in which end users purchase new indus- a somewhat challenging wireless
trial controller software and/or hardware Amanda Pelliccione is the research director
integration experience within the
are an automation upgrade (67%), a new at CFE Media, apelliccione@cfemedia.com.
installation (56%), and an operations/ past year. Source: Control Engi-
engineering upgrade (44%). neering 2016 Mobility, Ethernet,
3. Annual spend: Over the past 12
months, the average respondent’s com-
pany was estimated to have been spent M More
RESEARCH
and Wireless Study

69%
$158,000 on industrial controller soft- Control Engineering covers several research
ware and hardware; and an average of topics each year. of end users expect an
$157,000 is expected to be spent in the All reports are available at increase to their salary; 29% expect
next year on these products. www.controleng.com/ce-research
it to remain the same as 2016.
Source: Control Engineering 2017
How industrial controllers help Career & Salary Survey

Remote monitoring 65% 22%

Maintenance 55% 28% 35% of end users expect

to spend less than $20,000 on
Simulation 39% 33% HMI software and hardware in the
Mobile interface next 12 months. Source: Control
for alarming 29% 37%
Engineering 2017 HMI Software &
Mobile interface for
programming 21% 35% Hardware Study
Digital twins
of control systems 21% 27% Already doing
Modeling 18% 33% Considering doing More research
Control Engineering covers several
research topics each year.
More than half of respondents already use industrial controllers to help with
remote monitoring and maintenance tasks; another 39% use these products All reports are available at
for simulations, and 29% as a mobile interface for alarming. Source: Control www.controleng.com/ce-research.
Engineering

6 • December 2017 CONTROL ENGINEERING www.controleng.com

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input #4 at www.controleng.com/information
 INSIGHTS
INTERNATIONAL
Suzanne Gill, Control Engineering Europe

Address collaborative robot issues

Collaborative robots are a hot topic in manufacturing, and their use will grow as companies
implement Industrie 4.0. Consider safety and how collaborative robots complement a workforce.

C
ollaborative robots—and their safe be useful for high risk applications,” continued Shea
interaction with humans on the plant and Baek. “To use the speed and separation monitor-
floor—have become a hot topic in man- ing method, external safety devices, such as a safety
ufacturing. Discrete manufacturers are scanner, have been used to lower speed as a person
using these robots more often and their approaches the collaborative workspace.”
use will grow as Industrie 4.0 becomes more com-
mon on the plant floor. To address the safety issues Assess the risk, help the workforce
related to the interaction of robots and humans, the Improvements in safety technology allow industri-
ISO/TS 15066 standard was published in February al robots to be used in collaborative operations, pro-
2016 to provide guidelines on safety in collaborative viding many of the same benefits a cobot brings, along
robot systems. Four types of collaborative operation with increased speed and accuracy. Collaboration only
are listed 1) Safety-rated monitored stop; 2) Hand can be implemented after the appropriate risk assess-
guiding; 3) Speed and separation monitoring; and 4) ment, which is no different than choosing a cobot.
Power and force limiting. “What many are unaware of is that almost any
When it comes to the safety-rated monitored stop, robot is capable of collaborative operation with the
the robot system needs to stop before the human oper- appropriate safety mechanisms in place,” said Nigel
ator can access the collaborative workspace. The robot Smith, TM Robotics CEO. “It is the application that
can move as a non-collaborative robot only when defines the ability for human and machine to collabo-
there is no human operator in its workspace. The rate. Some manufacturers may specify a cobot assum-
robot system and the human operator can move, but ing it will work without caging... they may find their
not at the same time. This method cannot take advan- risk assessment shows the need for a safety cage or
tage of collaborative operation, and it requires safe- force limiters to keep human workers safe.” Added
guarding of a traditional industrial robot. Benefits are safety feature costs can make a cobot cost similar to
the ease and speed to resume automatic operation. that of an industrial robot, without the added capabili-
With respect to hand guiding operation, the ties of speed and accuracy, which usually isn’t the plan.
Manufacturers use human operator uses a hand-operated device and the Martin Walder, vice president industry at Schnei-
robots for collabora- robot system moves based on motion commands of der Electric in the U.K., believes the breakthrough to
tive operations more the operator. It is a kind of manually controlled oper- ensuring continued production facility modernization
often as Industrie 4.0 ation where the operator is in direct control of the lies in human-robot collaboration, where compact and
expands. Courtesy: robot system’s operation. This is considered automatic easy-to-use synergic automation will drive the market
Control Engineering rather than manual operation. in future years.
Europe In reality, only options 3 and 4 are used for benefi- “In many cases, robots can be employed to comple-
cial collaborative applications in industry, according to ment rather than replace workers. This concept, often
M More
INSIGHTS
Roberta Nelson Shea and Seungmin Baek of Universal
Robot. “Currently, most collaborative robots are inher-
ently designed to limit power and force. If the robot
known as ‘cobotics,’ teams operators and machines in
order to make complex parts of assembly processes
faster, easier, and safer,” Walder said. In meat packag-
KEYWORD: collaborative
robots detects a certain level of power or force, the robot stops ing lines, humans and robots working in the same area
Robots used to protect the human operator. Due to the safety-func- with a more flexible and efficient outcome.
collaboratively have tions for motion, speed, force, and power monitoring, “Robotic functionality provides full adaptability
safety considerations as the human and robot system can move at the same to new processes, reduces footprint requirements and
they complement human time in the same workspace,” said Shea and Baek. “As even enables the automation of manual tasks—often
workers.
long as the risk assessment is conducted properly, tra- the most dangerous, monotonous, and/or dirty ones
Collaboration between
robots and humans will be ditional guards and protective devices are not needed.” which help keep our workforces safe.” ce
imperative as Industrie 4.0 The power and force limiting method assumes the
grows. human can contact the moving robot system. “It is Suzanne Gill, editor, Control Engineering Europe;
GO ONLINE important to consider the impact to the human body This appeared on Sept. 29 on the Control Engineering
Read this article online during the risk assessment process. To prevent pain or Europe website, www.controlengeurope.com. Edited by
at www.controleng.com/ injury, the application also restricts payload and speed. Chris Vavra, production editor, Control Engineering,
international for more. As a result, the robot speed will likely be too low to CFE Media, cvavra@cfemedia.com.

8 • December 2017 CONTROL ENGINEERING www.controleng.com

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input #5 at www.controleng.com/information
 INSIGHTS
TECHNOLOGY UPDATE
Jon Breen, Breen Machine Automation Services LLC

Overcoming compatibility issues

with virtualization
Using a virtualization approach can save time, money, and resolve backup and recovery issues.

T
he proliferation of smart devices, software central processing unit (CPU), and network card—
tools, and networks has created many is not physically present but made to appear so with
new opportunities in the world of auto- software. Now imagine if instead of saving those old
mation and controls, but also has caused laptops under a desk, what if they were saved digi-
a lot of clutter on computers. Sometimes tally? Virtualization disconnects software from hard-
new software and features are celebrated and other ware that may be fragile or lacking a compatible
times cursed. One thing that’s always true is that the power supply. Virtualization allows migration to go
controls engineer will have one more piece of soft- from being hardware – dependent to hardware-free.
ware to manage (that is, another install, another A laptop can run old software and new software, and

‘
license, another backwards compatibility concern, each VM quickly can be backed up and restored.
Virtualization and another tool to keep in the support toolbox for Without ties to hardware, other benefits arise. A
the next 10 to 20 years). This isn’t likely to change any VM, stored on a laptop as a group of files, can be cop-
allows migra- time soon, so it’s important for an engineer to have a ied to network storage as a backup, or shared with col-
system that minimizes the management of these new leagues, preventing the need to install all the same
tion to go from developments. software. A VM also creates a separation between the
programming environment (the VM) and the host
being hardware- Managing software with virtualization environment (the laptop’s OS and applications), which
dependent Plenty of software management concerns exist means antivirus, user account control, and operating
beyond the sheer number of applications such as: system software updates aren’t typically needed in the
to hardware- What happens if my laptop breaks? What would it VM, where they might interfere with the program-
take to support this automation 10 to 20 years from ming software.

’
free. now? Will antivirus or user account control interfere The cost of virtualization can range from free to a
with this installation? Is this 32-bit (or 16-bit appli- few hundred dollars. Costs might include virtualiza-
cation compatible with my operating system (OS)? tion software (“hypervisor” $0 to $250) and laptop
How many days will this take to install? Controls hardware upgrades if already marginal ($0 to $300).
engineers commonly will keep a stack of old laptops What’s more important, and harder to measure, is
under their desks to keep backwards compatibility time. Time will be spent implementing and managing
and access to older OSs, but that’s obviously a gamble a virtualization approach, however, a lot of time will be
(old laptops aren’t known for reliability and can be a saved once a virtualization is in place.
cybersecurity risk), and it doesn’t scale very well into Get the team together and understand the orga-
the future. It’s more of a workaround than a real solu- nization’s software needs. Learn from other orga-
tion to the software management that is needed. nizations already using VMs and leverage their
Controls engineers can use virtualization to experiences to help develop a process. If possible, get
help manage software. Virtualization is usually some quick-start training on virtualization to ease the

M More
INSIGHTS
thought of on an enterprise scale, where
virtual machines (VMs) dwell on servers
and provide certain functionality across a
implementation process.
With current industry trends, there’s no end
in sight for the software burdens on control engi-
KEYWORD: Virtual machine network, like supervisory control and data neers. Virtualization is an approach that many have
Defining a virtual machine acquisition (SCADA) systems. Controls employed to keep access to older software, enhance
The benefits of a virtual engineers, on the other hand, usually bene- backup and recovery, save time by sharing, and stay
machine for engineers. fit the most from local virtualization, where secure without interfering with work. ce
CONSIDER THIS: the VM dwells on a laptop.
Jon Breen is the owner of Breen Machine Automa-
What cybersecurity
measures should be The benefits of a virtual machine tion Services LLC. Edited by Emily Guenther, associate
considered when working A VM is a computer where all hardware— content manager, Control Engineering, CFE Media,
with virtual machines? hard drive, random-access memory (RAM), eguenther@cfemedia.com.

10 • December 2017 CONTROL ENGINEERING www.controleng.com

INSIGHTS
TECHNOLOGY UPDATE
Kyle Voosen, National Instruments

Five technology trends for 2018

With advancements in automation, industries need to stay on top of the challenges ahead.

T
echnology has never advanced fast- circuit doubles about every two years) is dead. Though
er, with the global adoption of smart- it may be experiencing some health challenges, it’s not
phones, self-learning and agile robots, time to start digging the grave for the semiconductor
affordable genome sequencing, and and electronics market yet.
ubiquitous data storage. New computing techniques and new applications
The National Instruments (NI) Trend Watch for existing technology continue to advance the capa-
examines topics such as the mass deployment of the bilities for high-speed input/output (I/O) and process-
Industrial Internet of Things (IIoT), machine learn- ing. As previous architectural leaps, such as multicore
ing, and upcoming challenges in testing increasingly processors, have shown, the keys to riding the wave
connected and electrified systems. The following is a are the software tools and frameworks that leverage
summary of the five trends in NI Trend Watch 2018. the diversifying computing elements.

1. Three mandates to successfully 4. Vehicle electrification: Disrupting

manage IIoT efforts the automotive industry and beyond
Accenture estimates that 95% of companies will Ten years ago, a fully-mechanical coupling between
adopt the IIoT in the next three years to maximize the steering wheel and the front wheels was common.
uptime, optimize performance, and drive product However, the explosion of drive-by-wire technology,
and process innovation. Now, smart and connected combined with government mandates toward fully
“things” give companies opportunities for increased electric powertrains, has changed this paradigm—and
performance and lower costs, but managing these dis- it impacts more than just the automotive industry.
tributed systems is often an overlooked challenge. The reliance on power electronics and electric
Companies across all industries are adopting a motor drives adds complexity to control systems, and
new breed of disruptive platforms and ecosystems combining these control systems makes that complex-
that will transform businesses into engines of inno- ity grow exponentially. Directly, these factors increase
vation and growth by taking advantage of intelligent the complexity of vehicles. Indirectly, they create an
technologies. With IIoT technologies, they can har- immediate need for growth in infrastructure. Mak-
ness the benefits of these state-of-the-art platforms to ing it happen requires an interdisciplinary approach
reduce maintenance costs and improve asset utiliza- to building safe and reliable control systems among
tion. To successfully manage an IIoT strategy, compa- other needs.
nies must manage data, software configuration, and
remote systems. 5. Automating engineering insights
with machine learning
2. Progress of 5G is set Machine learning already has delivered beneficial
to disrupt test processes
5G signifies a generational transformation that will
profoundly impact businesses and consumers globally.
results in certain niches, but it has potential for a big-
ger and longer lasting impact because of the demand
for broad insights and efficiencies across industries.
M More
INSIGHTS
It promises faster data, shorter network response times As machine learning applications migrate from KEYWORD: Industrial
Internet of Things
(lower latency), instant access anywhere and every- the consumer space alongside development platforms
where, and the capacity for billions of devices. and converging IIoT edge node technology, business Trends to lookout for
in 2018.
Though test and measurement solutions will be leaders are looking to engineers and the next wave of
key in the commercialization cycle, 5G is set to disrupt machine learning to help find uptime, yield, and effi- The challenges that
advancements in technology
test processes because it requires a different approach ciency improvements in a sea of analog Big Data. bring across many industries.
to test than previous generations of wireless technol- As these advancements become a reality, it’s impor-
How these advancements
ogies. A platform-based approach that is flexible and tant to keep pace with how these developments will will impact processes within
software-configurable will be essential to the develop- make an impact across many industries. ce industries.
ment of this ecosystem. CONSIDER THIS:
Kyle Voosen is the section manager of data acquisition
3. Breaking Moore’s law and control marketing at National Instruments. Edited
What are the top
challenges engineers will
Recent publications say Moore’s law (the observa- by Emily Guenther, associate content manager, Control face as more companies
tion that the number of transistors on an integrated Engineering, CFE Media, eguenther@cfemedia.com. adopt an IIoT strategy?

www.controleng.com CONTROL ENGINEERING December 2017 • 11

 INSIGHTS
TECHNOLOGY UPDATE
Melissa Topp, Iconics

Using energy management

software to lower overall costs
Energy management software is designed to measure costs and deliver quantifiable results for
companies, from 5% to 25% annual energy cost savings. It also can be integrated with the cloud
to lower energy costs and provide more immediate, hands-on data for users.

M More
C
ompanies seek operational costs savings degrees in outside air temperature; or units in
and environmental responsibility. Energy component counts.
INSIGHTS management initiatives can help, which • Carbon elements, such as measured carbon
KEYWORD: energy involves ensuring all energy sources and dioxide or methane.
efficiency
users are identified and measured. Ener-
Energy management can gy management software analyzes factors such as: A comprehensive energy analysis tool should be
save operational costs and
help the environment.
able to deliver the back-end calculations, key perfor-
• Consumption rates, such as kilowatt hours mance indicator (KPI) analytics, rapid data historian
Energy management
software analyzes
(kWh) provided from electric, wind, solar, or storage and retrieval abilities, reporting, and visual-
consumption rates, costs, cogeneration sources; or l/hr from steam; or ization tools to manage and reduce an organization’s
conditions, and carbon cu3/h from gas; or gph from water. energy costs and carbon footprint. Users can receive
elements. • Cost for electricity, steam, water or gas. reports covering the energy cost per square feet, or
GO ONLINE • Conditions, such as people per hour for occu- average kWh based on degree days, or measured CO2
Read this article at pants; hours of equipment runtime; lumens per meter, or energy consumed per unit of product
www.controleng.com for of sunlight; cubic feet per minute (CFM) in produced. Real-time views into current energy trends
more articles about energy air handling units; square feet in zone footage; help catch problems early, which lead to better power
efficiency and the cloud. utilization and avoid costs.
Energy management Modern energy analytics tools in a software-as-
software can be used a-service (SaaS) model do not require on-premises
to measure how much computing hardware to interpret and analyze an orga-
energy is consumed nization’s energy data. Many cloud service providers
and provide a detailed also have adopted energy analytics software within
breakdown for compa- their massive data centers globally. An organization’s
nies. energy calculations can be computed on a server in a
data center being monitored by the same software.
Users have noted savings of between 5% and 25%
annually on utility bills without sacrificing building
occupant comfort using energy management soft-
ware. Another benefit is its scalability. Users can con-
nect sensors to monitor and measure one room, which
can be expanded to a floor, to a building, and an enter-
prise. City administrations have also implemented
energy management software because they have the
ability to show citizens quantifiable energy savings.
Adopting an energy management plan—wheth-
er installed on-site or connected to the cloud—is a
first step towards cost reduction and environmental
responsibility as companies continue to strive to do
more with less. ce

Software developments and the advent of the cloud can provide Melissa Topp is senior director of global marketing,
users with a detailed breakdown of energy usage in many ways and Iconics. Edited by Chris Vavra, production editor, Con-
even across multiple buildings. All graphics courtesy: Iconics trol Engineering, CFE Media, cvavra@cfemedia.com.

12 • December 2017 CONTROL ENGINEERING www.controleng.com

INSIGHTS
TECHNOLOGY UPDATE
Paul Figie, EZAutomation

Collect, optimize data

Use automation to collect pertinent operations data in the right format for
worthwhile outcomes. See three data structure tips.

T M More
wo common sayings about information an appropriately equipped industrial controller will
are contradictory: “You can never have give companies a competitive edge by making data
too much information,” and “Informa- more available for decisions when needed.
INSIGHTS
tion overload.” It’s challenging to use For effective data collection, assemble a diverse KEYWORDS:
data collection in real-time process- team and get them involved in the process of deter- Data acquisition, DAQ
es and to determine what data to collect and how mining what data should be collected or how it should Data can be useful in
often. A collective effort is required to make collec- be structured. What’s obvious to some may be over- real time and in historical
analysis.
tion schemes that work. looked by others. Set goals on how collecting data is
It’s common to make data collection schemes expected to improve the process or increase produc- Programmable logic
controllers can help collect
that generate files that never get looked at, not tion. Doing so helps with buy-in and drives the use of and store data.
because the information wasn’t useful, but because collected data from the beginning.
Data structure matters.
those who had access to that information did not Measuring production process improvement will
apply the data in a way that helped the process. keep team members accountable and make it easier to ONLINE
Other data collection schemes are used daily and duplicate success and minimize failures. Data struc- Find more information with
make production and processes more efficient. ture is important. Raw data collected over a period of this article online at
www.controleng.com.
time will be of little value, or may be too cluttered to
Data perception, presentation be used effectively. Three tips for data structure follow. CONSIDER THIS
Data that isn’t understood or is misinterpreted 1) Data should not be nested. Instead it should be How often do you revisit
may be useless, misleading, or even dangerous. Engi- kept simple, perhaps stored in a .csv or a table format what data is being collected
and how it’s being used?
neers need to have a good understanding of data col- for ease of use and manipulation. 2) For different data
lected and how it applies to the process. Data must be types, such as Boolean, integer, or string, consider
meaningful and applicable to increase its relevancy to storing each in separate files to help simplify the pro-
those who are going to use it. It must be presented in a cess of data analysis. 3) Collected data should include
clear format. Data and trends can be accessed through an option to send to and store in a secure SQL data-
smart phones, tablets, and other devices. base for future use. ce
Industrial programmable logic controllers (PLCs)
can incorporate Industrial Internet of Things (IIoT) Paul Figie is an application engineer at EZAutoma-
capabilities by using message queuing and the mes- tion; edited by Mark T. Hoske, content manager, Con-
sage queuing telemetry transport (MQTT) protocol, trol Engineering, CFE Media, mhoske@cfemedia.com.
which can send real-time data to the cloud and relay it
to smart phones, tablets, and other devices. Historical
data points to past trends, helps analyze mistakes, and
highlights corrective actions to make the process more
effective. Analysis and decisions take time. Historical
data can be stored on PLCs that can use a USB drive
and then used for later analysis.
Combining real-time and historic data can help
predict and take corrective action, which will help
companies to be more productive. Data collection in
the automotive, oil and gas, pharmaceutical, pack-
aging, and other process industries plays a vital role.
It helps personnel of all departments know where
they stand, what is their target, and what they have
achieved. What if machine-level controllers like a PLC
or a programmable automation controller (PAC) have Data logging feature in the EZRack PLC from EZAutomation can
a built-in data collection and storage feature? What if structure and store data on a USB flash drive plugged into a CPU.
the same controllers could send data to a cloud? The resulting .csv file can be opened in Microsoft Excel and easily
The IIoT is emerging, and implementing IIoT in manipulated. Courtesy: EZAutomation

www.controleng.com CONTROL ENGINEERING December 2017 • 13

INSIGHTS Digital edition? Click on headlines for more details.
NEWS See news daily at www.controleng.com/news

Electronics manufacturing driving

industrial robotics market growth
Global sales of industrial robots rose times for electronics manufacturers. Indus- screens, assemble connectors and other
16% in 2016, bringing the world market trial robots inherently are more precise subassemblies, apply adhesives and seal-
value up to $13.1 billion. Industrial robot than humans, and have a major impact on ants, perform inspections and tests, and
sales are forecasted to grow at a faster assembly work that revolutionizes the rest even populate and coat circuit boards.
rate in 2017, and sustain this rapid rate of of the electronics supply chain. They play a vital role from the start of pro-
growth through 2020. Industrial robots can place parts faster duction right up through to the point of
While industrial robot sales have grown and more accurately, clearing the way not delivery.
consistently, the dynamics of this growth only for smaller electronics, but also faster Industrial robots are important in
are changing. For decades, the automotive production and higher throughput. This, the electronics manufacturing industry
industry was the major driver of growth in turn, allows manufacturers to optimize and enable not only major supply chain
in industrial robots. However, in 2016 their supply chains by reducing lead times changes but revolutionized production
the electronics manufacturing industry and by moving production closer to the processes. 2016 saw strong growth in
accounted for nearly as many robot ship- product’s destination. industrial robotic sales in the electronics
ments as the automotive industry. manufacturing industry, and adoption
Industrial robot sales jumped 41% in Industrial robot applications rates will likely increase.
the electronics industry in 2016. As robots Industrial robots perform a wide vari- The electronics industry is on par with
become smaller, cheaper, and more pre- ety of tasks in electronics manufacturing. the automotive industry and is adopting a
cise, these manufacturers increasingly are Many of them involve advanced vision wider range of robotic solutions than pre-
adopting robots to combat the enormous systems and sensors to accommodate for viously used.
demand for batteries, chips, and displays. task variations and careful handling of This article originally appeared on the
Robots allow for miniaturization, delicate parts. Robotics Online Blog. Robotic Industries
increased throughput, and reduced lead Robots are used to handle display Association (RIA) is a part of the Associa-
tion for Advancing Automation (A3), a
CFE Media content partner. Edited by Chris
Industrial Internet group announces Vavra, production editor, Control Engineer-
ing, CFE Media, cvavra@cfemedia.com.
digital solar plant testbed
The Industrial Internet Consortium (IIC) announced the Digital Solar Plant Headlines
testbed. The testbed is led by IIC members LTI, a global technology consult-
ing and digital solutions company, and GE Digital. It will deploy in multiple
online
phases at an L&T Solar plant in Rajasthan, India, beginning in early 2018. Top five Control Engineering articles
Nov. 13-19: Most visited articles included
“Testbeds are the major focus and activity of the IIC and its members,”
stories on the Engineers’ Choice finalists,
said IIC executive director, Dr. Richard Soley. “Our testbeds, including the industrial mobile robot safety standards, pro-
new Digital Solar Plant testbed, are where new technologies, applications, cess engineers and analytics, the IoT and
products, services and processes—the innovation and opportunities of the ERP, and a motor and drive webcast Q&A.
industrial Internet—can be initiated, thought through and rigorously tested Ensuring OT cybersecurity
to ascertain their usefulness and viability before coming to market.” Cybersecurity breaches that affect operation
“Utility companies face several issues as global interest in solar energy technology (OT) systems and devices.
soars—from mitigating operational and regulatory risks to maintaining effi- Master data management’s
ciencies and improving capacity utilization,” said Rohit Kedia, chief business benefits for ERP
officer, manufacturing and ERP, LTI. Master data management (MDM) is a tech-
“Renewable energy is a transformative solution that will meet energy as nology-enabled business discipline.
well as economic challenges globally,” said Shyam Varan Nath, director, tech- Hurricanes create an ill wind,
nology integrations, IoT/industrial Internet at GE Digital. “Using real-time but PMI remains strong
data analytics, utilities also can ensure that all of their assets are working Four reasons why electric
properly and that their plants are running efficiently.” motors overheat
- Edited from an Industrial Internet Consortium (IIC) press release by CFE Using a PHA for process valve safey
Media. The IIC is a CFE Media content partner. Organization outlines 10 manufacturing
predictions for 2018

14 • December 2017 CONTROL ENGINEERING www.controleng.com

 INSIGHTS
®
THINK AGAIN
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Content Specialists/Editorial
Mark T. Hoske, Content Manager
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Jack Smith, Content Manager
Top 10 topics for 2018
630-907-1622, JSmith@CFEMedia.com Hottest 2018 topics in automation, controls, and instrumentation are
Kevin Parker, Senior Contributing Editor, IIoT, OGE
630-890-9682, KParker@CFEMedia.com here, but don’t take my word for it; help write future history.

P
Emily Guenther, Associate Content Manager
eguenther@CFEMedia.com
Amanda Pelliccione, Director of Research
978-302-3463, APelliccione@CFEMedia.com
rediction articles are fun, especially the control loop and put information where
Joy Chang, Digital Project Manager the 10 most important Control Engi- it’s needed for smarter, faster, and more cost-
JChang@CFEMedia.com neering topics for 2018. These are dif- effective decisions, whether automated or not.
Chris Vavra, Production Editor
ficult choices, given the 2018 topics
6. Industrial Internet of Things (IIoT)
CVavra@CFEMedia.com
at www.controleng.com/2018articles. Selec-
Contributing Content Specialists tions are based on past site traffic, discussions, device and system integration ensure that
Frank J. Bartos, P.E., braunbart@sbcglobal.net and input from our research, and my obser- information technologies (IT) and opera-
Suzanne Gill, Control Engineering Europe
suzanne.gill@imlgroup.co.uk
vations in industry since 1987, but don’t take tional technologies (OT) are working more
Ekaterina Kosareva, Control Engineering Russia my word for it. Think again about effectively together, locally and
ekaterina.kosareva@fsmedia.ru what’s important to you, prioritize connected to an increasing wealth
Wojciech Stasiak, Control Engineering Poland
wojciech.stasiak@trademedia.us
your list, and help write the future of cloud-based resources, such as
Lukáš Smelík, Control Engineering Czech Republic of Control Engineering. Learn how artificial intelligence (AI), machine
lukas.smelik@trademedia.us at www.controleng.com/contribute. learning, predictive analytics, and
Aileen Jin, Control Engineering China
aileenjin@cechina.cn 3-D printing ecosystems.
Predictions for 2018
Editorial Advisory Board 7. Cybersecurity: Advances
www.controleng.com/EAB
Doug Bell, president, InterConnecting Automation,
1. Controllers: factory auto- Mark T. Hoske, in packet inspection and device
www.interconnectingautomation.com mation control, process control Content Manager
designs augment cybersecurity
David Bishop, president and a founder systems, edge computing, embed- even as a greater amount of train-
Matrix Technologies, www.matrixti.com
Daniel E. Capano, president, Diversified Technical Services Inc.
ded controls, motion controls, ing and higher levels of awareness
of Stamford, CT, www.linkedin.com/in/daniel-capano-7b886bb0 and robotics controls (and robotic designs) are required. Like safety, cybersecurity is
Frank Lamb, founder and owner
Automation Consulting LLC, www.automationllc.com
are advancing quickly. everyone’s responsibility.

2. Product innovation in automa- 8. Engineering Leaders Under 40:

Joe Martin, president and founder
Martin Control Systems, www.martincsi.com
Rick Pierro, president and co-founder
Superior Controls, www.superiorcontrols.com tion, controls, and instrumentation: Annual recognition (in September) of
Mark Voigtmann, partner, automation practice lead Engineers’ Choice Awards are announced upcoming talent fueling the next-generation
Faegre Baker Daniels, www.FaegreBD.com
in February; these products can help of innovations in automation, controls, and
increase the effectiveness of your next instrumentation.
CFE Media Contributor implementation.
Guidelines Overview 9. Training is increasingly important
Content For Engineers. That’s what CFE Media
stands for, and what CFE Media is all about – 3. Career and salary survey: Bench- as the demographic crunch continues, and
engineers sharing with their peers. We welcome marking provides comparisons; next steps more-intuitive human-machine interfaces
content submissions for all interested parties in
engineering. We will use those materials online, on and other advice are provided. (HMIs) and next-generation augmented real-
our website, in print and in newsletters to keep ity (AR) are helping.
engineers informed about the products, solutions
4. Advanced controls include propor-
10. Energy efficiency, especially mea-
and industry trends.
www.controleng.com/contribute explains how tional-integral-derivative (PID) control:
to submit press releases, products, images and
graphics, bylined feature articles, case studies, white acquiring, analyzing, and integrating input surement and monitoring to make energy
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* Content should focus on helping engineers solve
problems. Articles that are commercial or are critical loop control and make open-loop control ing processes, and linked to enterprise and
of other products or organizations will be rejected. designs more effective. supply chain systems. Sensors, motor and
(Technology discussions and comparative tables may
motion efficiency, and networking play criti-
5. Communications: advanced industrial
be accepted if non-promotional and if contributor
corroborates information with sources cited.) cal roles.
* If the content meets criteria noted in guidelines,
expect to see it first on our Websites. Content for our Ethernet and wireless communications con-
e-newsletters comes from content already available on nect the sensors, controllers, and actuators of Learn more and share your knowledge
our Websites. All content for print also will be online.
All content that appears in our print magazines will in Control Engineering articles, research,

M More webcasts, CFE Edu training, digital reports,

appear as space permits, and we will indicate in print
if more content from that article is available online.
newsletters, and CFE Media supplements,
* Deadlines for feature articles intended for the print
magazines are at least two months in advance of the INSIGHTS such as Global System Integrator Report,
publication date. Again, it is best to discuss all feature
articles with the appropriate content manager prior to www.controleng.com/2018articles IIoT for Engineers, and Oil & Gas Engineer-
submission. www.controleng.com/contribute ing. Thank you for your support. ce
Learn more at: www.controleng.com/contribute

CONTROL ENGINEERING December 2017 • 15

 TAKE YOUR OPERATIONS

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sponsored by:

2017 Programmable Controller

Software & Hardware Study
Turning research into insights makes for better business decisions
This study was conducted by Control Engineering to acquire information related to the
buying and specifying habits of automation engineering professionals for programmable
controller software and hardware. Respondents to the Control Engineering 2017
Programmable Controller Software & Hardware Study unveiled several key findings
regarding what end users expect and how they purchase or specify industrial
controller software and hardware.

According to the study, the top uses for programmable controller software
or hardware are discrete and continuous manufacturing (22% primary, 22%
secondary), and continuous manufacturing (22% primary, 17% secondary). In
addition; in the past 12 months, respondents spent an average of $157,678 on
industrial controller hardware and software—with 21% having spent $200,000
or more. Eighty-two percent of respondents expect to buy industrial controller
software or hardware in the next 12 months. On average, respondents plan to
use nine controllers over this period.

Access the 2017 Programmable Controller Software & Hardware report with additional
findings and insights. www.controleng.com/2017ControllersReport
 ANSWERS
FEATURE ARTICLES

One cable automation

25 combines communication
and power
New connector technologies expand EtherCAT
and EtherCAT P communication with additional
power supply options.

COVER STORY
Virtualized manufacturing,
18 simulation opportunities Courtesy: Beckhoff Automation

A simulated factory floor can monitor parameters,

expose production gaps, highlight cost inefficien-
cies, reduce carbon footprint, and, applied to one
product, can simulate its role in the real world
while still on the drawing board.
M More
ANSWERS
More Inside Machines online
www.controleng.com
3-D robotic welding
21 simulation benefits
Related topics are available under the
“Discrete Manufacturing” navigation menu.
Teaching robots how to weld using 3-D simulation
is beneficial because welding is a complex,
precise process that cannot be explained or INSIDE MACHINES
taught easily to humans. Picking the right
M1 discrete sensor for a
machine application
Customers need process
23 control building blocks and
standardization
There are many considerations for picking
a discrete sensor for a machine application.
These include if the sensor is being used for
Despite the demand for standardized communi- position detection or part detection or if the
cation protocols among manufacturers, both the application is hazardous.
manufacturers and end users face challenges
when it comes to agreeing on a path.

Wireless as a means to
M4 overall equipment efficiency
M More
ANSWERS Accurate machine run-time data helps determine
why production goals aren’t met.
Check out the IIoT: Machines, Equipment, & Asset
Management digital report at: www.controleng.com

www.controleng.com CONTROL ENGINEERING December 2017 • 17

ANSWERS
COVER STORY: SIMULATION
Mayank Pandya, L&T Technology Services

Virtualized manufacturing,
simulation opportunities
A simulated factory floor can monitor parameters, expose production gaps,
highlight cost inefficiencies, reduce carbon footprint, and, applied to one
product, can simulate its role in the real world while still on the drawing board.

T ‘
he key to transforming manufacturing is
to take operations off the floor by virtu-
Digital manufacturing allows
alizing functions, creating simulations,
and using those digital models to create effective identification of pro-
advantages. Design and assembly must
expand their roles and produce two products—a duction bottlenecks, which
virtual model that contains pure information about
the product as well as its actual physical counterpart.
Digitalization has enabled us to do exactly that.
permits factories to meet peak
Digital manufacturing empowers operators with
the agility to scale production volume and deliver demands with optimally ad-
multiple product variants early in the process—factors

’
essential to maximize program revenue and ultimate- justed output.
ly, profits. At its inception, the manufacturing process
can be virtually conceptualized at a prototype center
and subsequently transferred to volume production Virtual product prototyping techniques have
centers, increasing business flexibility and cost control been characterized by the same 3-D wireframe
within the global marketplace. technique that George Lucas used to create
Furthermore, digital manufacturing makes the Death Star in the original 1977 “Star Wars”
room for operators to freely exchange design movie. Engineering has further leveraged the
knowledge and technical knowledge. process, layering virtual models with scanned

M More
ANSWERS
In turn, digital manufacturing allows
effective identification of production
bottlenecks, which permits factories
samples to identify suitable materials for manu-
facturing the product.
However, as sustainability has become a criti-
KEYWORDS: Simulation, to meet peak demands with optimally cal performance indicator, the process of testing
virtualization
adjusted output. and selecting materials needs to be simplified.
Simulating manufacturing has
advantages for operations and In collaboration with a leading soft- Virtual prototyping must therefore support con-
product design. ware multinational, a French porcelain servation goals—saving valuable resources and
Use of a digital twin allows manufacturer is overhauling its man- promoting sustainability.
simulation of how something ufacturing ethos by taking the entire
will behave before changes are design and development process to the Data-driven approach
made.
cloud. The platform aims to do away Following the prototyping stage, manufactur-
Modeling increases
opportunities to correct problems with cost-intensive physical prototyping ing begins to struggle with the need to replicate
at a lower lifecycle cost. practices, enabling the manufacturer to the design and functionality of the first product.
create and validate virtual models that Currently, this requires expensive physical quality
CONSIDER THIS
can serve as reference points for devel- audits with debatable accuracy.
What part of your operations
would most benefit from oping molds. The company also plans to Addressing this particular challenge will
simulation, modeling, and use of digitize its existing catalog—preserving require a data-driven approach from an engineer-
a digital twin? 150 years of design contributions. ing perspective. The manufacturing process will

18 • December 2017 CONTROL ENGINEERING www.controleng.com

Building blocks of virtual manufacturing, simulation

Cover image:
Although vir-
tual manufacturing
started out as a
way to design and
test tools, it has
grown to become
a powerhouse for
supporting pro-
duction processes
and even product
development. Digi-
tal models capture
information about
the product for
rapid prototyp-
ing and eventually
mass production on
the factory floor.
Courtesy: L&T Tech-
nology Services

need to capture product data as it is being built,

concurrently crafting a virtual model that mirrors
the physical product.
This sets the stage for implementing a product
‘ A product specification management
(PSM) system that can ensure quality
specification management (PSM) system that can as part of the product lifecycle manage-
ensure quality as part of the product lifecycle man-

’
agement process. On page 20, see the five steps for ment process.
digital replicas and rapid prototyping.

Manufacturing ecosystem The case for virtualizing manufacturing is

The idea is to work towards building a man- strengthening. When an enterprise uses physical
ufacturing ecosystem that is capable of creating prototypes to carry out design iterations, certain
components and tools on demand in space, on material classes, like metal, cannot be digitally
land, or at sea. At present, laser-forming tech- fabricated or machined at a favorable cost. If the
nologies and digital design data is being used to final production material varies from the pro-
transmute powder materials into complex avionic totyping material, the material properties of the
structures, such as F/A-18E/F ducts. In a process end product cannot be accurately predicted, even
called selective laser sintering, titanium and other when a company implements rapid prototyping
materials are used to print parts small and large. or 3-D printing.

www.controleng.com CONTROL ENGINEEERING December 2017 • 19

ANSWERS
COVER STORY: SIMULATION

When it comes to structural design, tea cups,

airplanes, and automobiles involve the same set
of challenges. Material selection, durability, and
design feasibility will need to be aligned with how
‘ A simulated factory floor

can monitor various param-

the product interacts with real-world forces, heat,
and vibration. In this context, virtual manufac-
turing has been able to take finite element analy- eters to expose gaps in the
sis (FEA) to the next level. Welding simulations
that factor in thermal and residual stress will help
optimizing tooling design and the actual welding production process, highlight
process. R&D efforts are under way to develop
FEA software to simulate and develop predictions
cost inefficiencies, and
5 STEPS for digital replicas,
’
reduce carbon footprint.
rapid prototyping
Digital replicas and rapid prototyping can be implemented for automatic process optimization. Once inte-
grated with the control system, it should be able
in five steps.
to re-calibrate tools on the factory floor to accept
design, tooling, fabrication or material changes
1. Integration and data collection. without human intervention.
Physical inspection hardware such as scanners, coordinate
measuring machines, and gauges, can be integrated with Digital twins simulate everything
sensors. Manufacturing’s future lies beyond using virtual
product information to improve output quality.
2. Data transfer of collected data. We are close to practically replicating the entire
factory floor using amalgamated data from the
Data capture, while the product is making its round on the
entire production ecosystem, creating a digital
assembly line, needs to be relayed to the middleware layer. twin.
A major technology conglomerate already is
3. Software restructuring of data. exploring the concept, creating working simula-
At this point, automated mechanical design software tions of wind farms to forecast equipment failure
refines and structures the data, creating a perfect as-built and increase daily power output by 20%.
replica. In this regard, virtual commissioning allows
operators to comprehensively verify the sustain-
ability of a manufacturing system by creating a
4. Replica storage for reference, use. virtual plant and linking it to a real controller.
The replica is stored in the manufacturing execution system This requires the plant simulation model to be
for reference and homologation (certifying to required reg- described fully, down to the level of sensors and
ulatory standards and specifications). actuators. By connecting the model to a real con-
troller, engineers can detect potential errors of
5. CAD, 3-D printing anticipate needs. control programs long before the actual commis-
sioning stage.
For maintenance, repair, and overhaul (MRO) operations, a
A simulated factory floor can monitor various
network-centric manufacturing environment can use com- parameters to expose gaps in the production pro-
puter-aided design (CAD) data to almost organically grow cess, highlight cost inefficiencies, and reduce car-
production parts. These steps can be used to implement bon footprint. The same concept can be scaled
rapid engineering changes in the field or at the mainte- down, and applied to a product in isolation, to
nance depot. Three-dimensional printing technology is understand how it would perform in the real
being used by leading aerospace original equipment man- world without taking it off the drawing board. ce
ufacturers (OEMs) and others to streamline product design
Mayank Pandya is head-manufacturing engineer-
and build operations—enabling them to deliver world-class
ing, L&T Technology Services, a Control Engi-
support and eliminate the need for warehouse tools and neering Content Partner. Edited by Mark T. Hoske,
spare parts. content manager, Control Engineering, CFE Media,
mhoske@cfemedia.com.

20 • December 2017 CONTROL ENGINEERING www.controleng.com

ANSWERS
COVER STORY: SIMULATION
Tanya M. Anandan, RIA

3-D robotic welding

simulation benefits
Teaching robots how to weld using 3-D simulation is beneficial
because welding is a complex, precise process that cannot be
explained or taught easily to humans.

E M More
lements of advanced motion control, system consists of a 16-panel audiovisual wall
3-D vision, and robotic control combine that displays 2-D and 3-D images. It’s also porta- ANSWERS
in 3-D simulation software for robotic ble, which makes it easy to dismantle and set up.
KEYWORD: robot,
welding. The future in robotic welding is “It’s a great tool for us,” said Brendan Brown, simulation
digital and simulation helps show possi- virtual solutions engineer at Genesis Systems 3-D simulation can be
bilities that might not have been considered before. Group. “With the 3DG Environment, we’re able used to teach robots how
Genesis Systems Group uses simulation to to draw clients into the experience and give them to weld.
visualize and demonstrate complex or large-scale a real-life feel for what they will get with one of Teaching laser welding
robotic processes before anything is built. This is our systems. They get to see what we do upfront to robots can reduce
especially helpful for welding, which is a complex, and all the pre-order work we do to give them the distortion and deflection
and improve accuracy
precise process that cannot be easily explained or right solution.” overall.
taught to humans. They also use the 3DG system to conduct While robots can be
The 3DG Environment at the Genesis Systems reviews with their in-house design and tooling taught how to weld,
Group Virtual Solutions Center is designed to groups for a collaborative process. humans need to have a
combine virtual reality and immersive 3-D visu- “You wear a set of regular 3-D glasses like you strong understanding of
the process.
alization to visualize a robotic process in the con- would get at a movie theatre,” Brown said. “Then
cept and design phases. The 3DG technology is with the joystick, you can drive around the GO ONLINE
designed to ergonomically evaluate parameters model, to go around the machine, get underneath Read this story online at
such as welding torch access and robot reach. The it, come inside, and look at it from all angles.” www.controleng.com to
learn more about welding’s
benefits in manufacturing
and see additional stories
from the RIA.
CONSIDER THIS
What other ways can
robotic simulations help
manufacturing?

Figure 1, cover
image: Immersive 3-D
virtual reality technol-
ogy simulates robotic
welding processes
for more efficient
design and concept
review prior to build.
All images courtesy:
Robotic Industries
Association (RIA)/
Genesis Systems
Group LLC

www.controleng.com CONTROL ENGINEEERING December 2017 • 21

ANSWERS
COVER STORY: SIMULATION

‘ Simulations show how

traditional MIG welding
might have 5 mm of draw or
deflection in it, but with laser

’
welding it’s down to 1 mm.

and distortion. We’ve done simulations to show

them. One gentleman in my department does strictly
weld distortion and heat analysis. He can show a cus-
tomer how with traditional MIG welding on a cer-
tain part you might have 5 mm of draw or deflection
in it, but with laser welding it’s down to 1 mm.”
Figure 2: Reach simulation study for a robotic laser welding applica-
tion shows possible problems before setup. Laser welding benefits
Across the hall from their Virtual Solutions Cen-
ter is Genesis’ Automated Solutions Center, where
they test technologies such as remote laser welding
and a laser seam stepper.
Genesis is using the robotic laser seam stepper
to test customers’ parts that have been traditionally
spot-welded. They also have a few robotic systems
already in the field.
The laser seam stepper is a servo-driven, self-
contained laser head. “One of the advantages is that
you don’t need the large laser safety cabinets com-
mon with most laser welding processes,” Brown said.
“The robot will move above the part, then
drive the laser head down, basically applying force
with the head, which helps push the two materi-
als together. Then it runs a bead up to 40 mm in
length. You don’t need the giant light-tight enclo-
Figure 3: Robotic laser seam stepper combines clamping force with sure, and a lot less fixturing is involved. It’s a much
laser welding technology to replace traditional resistance welding. better finish than a traditional spot weld and cer-
tainly more consistent.”
Brown said advanced welding technologies such
For example, a welding robot on a three-axis as remote laser welding and the laser seam stepper
gantry is positioned to MIG weld the frame of a still prompt the same concerns for part fit-up and
large dump truck used in the mining industry and other critical variables as do conventional welding
the multicolored sections represent the part. processes. The process still has to be understood in
“Some of these parts are 40 ft long,” Brown said. its entirety to successfully automate it. ce
“This part requires multi-pass, heavy thick-plate
welding. It’s a 48-hour cycle time to weld one piece. Tanya M. Anandan is contributing editor for the
This part actually grew 2- to 3-in. during the weld- Robotic Industries Association (RIA) and Robotics
ing process just because of the heat and draw on it Online. RIA is a not-for-profit trade association dedi-
(distortion).” cated to improving the regional, national, and global
Brown said the simulation environment allows competitiveness of the North American manufactur-
them to demonstrate advanced processes to their ing and service sectors through robotics and related
clients that they may not have imagined were fea- automation. This article originally appeared on the
sible. The automotive and appliance industries are RIA website. The RIA is a part of the Association for
starting to take a closer look at laser welding. Advancing Automation (A3), a CFE Media content
“We won a handful of customer orders because partner. Edited by Chris Vavra, production editor, Con-
we were able to laser weld, which has a lot less heat trol Engineering, CFE Media, cvavra@cfemedia.com.

22 • December 2017 CONTROL ENGINEERING www.controleng.com

 ANSWERS
PROCESS | STANDARDIZATION
Chris Sullivan, Valin Corp.

Customers need process control

building blocks and standardization
Despite the demand for standardized communication protocols among
manufacturers, end users and manufacturers face challenges when trying
to agree on a path.

I
n the industrial refining marketplace, pro- However, after the internet began to take hold
cess control building-block manufacturers of of the market, that relationship diminished
transmitters, valves, and flowmeters are posi- due to the availability of online informa-
tioning themselves to become single-source tion and product offerings. Engineers
suppliers for their customers. Although the and purchasing personnel found that
manufacturers’ portfolios are attractive and sup- they could choose what was best for
port most engineering applications, the future their processes without a middleman.
desire of the marketplace is to convert to univer- Unfortunately, understanding the
sal language protocols that communicate with qualified products available in the mar-
the best-in-class building-block products in their ket and where to find them took a great deal
applications. of time that the engineers didn’t have.
What refineries really want are the best-in-
class products that employ a universal language
that will communicate with their legacy instru-
This brought back a rise in the rela-
tionship between engineers who were
experts in their processes and sales-
M More
ANSWERS
mentation to improve productivity and the bot- people who were experts in their mar- KEYWORD: Process control
tom line. Universal language protocols may reduce kets and products. Refineries wanted Selecting best-in-class process
instrumentation is what is best for
process control building-block variable risk and a single-source supplier to take care the customer, but standardization
increase process throughput. Customers are look- of their product and process parts- is becoming more necessary
ing for their suppliers to become partners who buying, isolating the variety of prod- for profitability because of the
help improve their processes, standardize commu- ucts available to them. These suppliers difficulty of communicating
nications protocols, and drive their profitability. became single-source and the only between parts that are not from
the same supplier.

‘
resource a refinery could use for pro-
The oil refineries in today’s
cess-control building blocks. marketplace are using legacy
Universal language protocols However, there are a few concerns technology that has not been
with using a single-source supplier. upgraded to 21st century
may reduce process control standards because what they
are using works for their current
1. Best-in-class product ideal for profitability models.
building-block variable risk and the application may not be on the The market has decided that
refinery’s approved vendor list, and the next step in employing

’
therefore, unavailable for purchase to process control building blocks
increase process throughput. the single-source supplier. is universal communication with
manufacturers and distributors
that can improve their processes
Despite the demand for standardized communi- 2. A single source prevents learning and profit.
cation protocols among manufacturers, both the about better products that may be avail-
manufacturers and end users face challenges when able to become qualified products. GO ONLINE
it comes to agreeing on a path. Read this story online at
www.controleng.com for
3. If a single source is unable to more information on process
The pitfalls of single-source suppliers provide a product due to floods and control building blocks and
Before the internet, business between manu- natural disasters, the refinery has standardization.
facturers and customers was carried out between no alternative to replace the single- CONSIDER THIS
engineers and salespeople. Businesses received sourced product it needs. This can How can a product help make
their information, parts, and application under- mean a serious loss of productivity your processes more efficient
standing from competing sales representatives. and profits. Of course, pulling process and profitable?

www.controleng.com CONTROL ENGINEEERING December 2017 • 23

 ANSWERS
PROCESS | STANDARDIZATION

control building blocks from multiple sources has universal protocols in their process control build-
an internal cost, but the improved process perfor- ing-block strategies to bring these older refiner-
mance and uninterrupted process flow may out- ies up-to-date. The challenges refinery engineers
weigh the cost of finding out. and procurement personnel have in making this
transition are equally vast. Even though upgrad-
What is best for the consumer? ing processes can be expensive, the reward for
For obvious reasons, selecting best-in-class manufacturer and customer is increased product
process instrumentation is what is best for the throughput and profitability.
customer, but standardization is becoming more Refining customers also need manufacturers to
necessary for profitability. This is due to the dif- provide experience and knowledge of the customer’s
ficulty of communicating between parts that are process to improve it. Manufacturers can provide
not from the same supplier. For example, an engi- this capability through their distributors. With stan-
neer might find a transmitter that works best with dardization comes the risk of creating a commodity
his or her process, but can’t properly communi- mentality in the marketplace.
cate with the much-older flowmeter already in To overcome this, distributors must provide
good technical knowledge of their customers’ pro-

‘
cesses including not only instruments they are
providing, but a clear understanding of all avail-
Cost management, unit performance, able products on the market. Distributors now
can become the resource of information, experi-
experience, and process knowledge, ence, and best-in-class products for their refin-
ing customers. A partnership can be created to
along with universal communication strive toward universal protocol communication
for process control building blocks and encourage

’
the marketplace to continue to strive for that out-
protocols, are all part of the answer. come. It is in the best commercial interest of all.

Future standardized communication

the process because they are from different sup- Refinery customers always will ask, “How can a
pliers. This requires the engineer to make a soft- product help me make my process more efficient
ware upgrade in the process to compensate for the and profitable?” Cost management, unit perfor-
different language protocols. The problem here is mance, experience, and process knowledge, along
a software upgrade is essentially just a Band-Aid with universal communication protocols, are all
on the process, and doesn’t allow it to run at maxi- part of the answer.
mum efficiency. Manufacturers face the challenge of convinc-
Another concern is that with the attrition rate ing their customers to upgrade processes with
of older personnel retiring, the software upgrade their products, and standardized communication
employed may be outside the awareness or not among process control building blocks could give
understood by the new personnel inheriting the them an advantage.
process. In a single application, this may not be a The refinery will be more inclined to invest and
concern. However, in hundreds of applications it improve their process because the universal proto-
may be. col language will make it easier and more efficient.
Essentially, the customer is the market, and the
Making the change market has decided that the next step it wants to
The challenges manufacturers must overcome take in employing process control building blocks
to realize a universal protocol are enormous. Some is universal communication with manufacturers
refining customers have been making oil products and distributors that can improve their processes
since 1900. Oil refineries in today’s marketplace are and profit.
using legacy technology that has not been upgrad- Suppliers who provide this capability will have
ed to 21st century standards because what they are priority over those who do not. ce
using works for their current profitability models.
For refining customers who want to upgrade their Chris Sullivan is director, refining and petrochemi-
refinery’s technical capability and make the invest- cal, at Valin Corp., a technical solutions provider for
ment, universal protocol is being requested to sup- the technology, energy, life sciences, natural resources,
port their needs. This includes communicating to and transportation industries. Edited by Jack Smith,
legacy instrumentation seamlessly, securely, and content manager, CFE Media, Control Engineering,
robustly. Manufacturers are being asked to consider jsmith@cfemedia.com.

24 • December 2017 CONTROL ENGINEERING www.controleng.com

ANSWERS
POWER OVER ETHERNET
Sree Potluri and Andy Garrido, Beckhoff Automation

One cable automation combines

communication and power
New connector technologies expand EtherCAT and EtherCAT P
communication with additional power supply options.

C
onnecting individual field devic- for many applications. Different sections in a network
es, decentralized terminal boxes, and can be connected by selecting appropriately designed
machine modules using one cable is combined power and Ethernet cables for devices
accomplished by combining industrial and components according to power requirements.
Ethernet communication via EtherCAT Unrestricted openness for mixed network topologies
with the power supply required by the connected enables flexible transitions between:
components. For the 24 V field level, this was imple-
mented using the EtherCAT P technology expan- • EtherCAT P communication with integrated
sion connected via special M8 connectors. To provide power supply (one cable solution with M8
additional power supply capabilities via one cable, connector)
new ENP and ECP connector types combine Ether-
CAT or EtherCAT P communication with additional • One cable solution using hybrid cables that com-
power conductors in one cable. They are easy to use, bine an EtherCAT or EtherCAT P communica-
are mechanically coded to prevent installation errors, tion element with additional power conductors
and offer an IP67 protection rating. (one cable solution with the new ENP or ECP
The flexible single-cable automation design works connectors)

With various performance classes for the connection of components via the ECP and ENP connector variants, One
Cable Automation provides the ideal foundation for modular machine and plant design. Courtesy: Beckhoff Automation

www.controleng.com CONTROL ENGINEEERING December 2017 • 25

 ANSWERS
FEATURE

• A conventional two-cable solution with sep- EtherCAT P, 24 V, one cable

arate power supply (EtherCAT via M8/RJ45 With EtherCAT P, EtherCAT technology has
connector or EtherCAT/EtherCAT P via ENP/ expanded to combine high-speed EtherCAT com-
ECP connector). munication with a 24 V system and peripheral power
supply (US or UP), in a standard Ethernet cable. Spe-
ECP and ENP connector types implement the cial M8 connectors were developed for EtherCAT P
combination of communication and power elements with mechanical encoding that eliminates possible
in different performance classes that range from 3 confusion with connectors used for standard Ether-
amps to 64 amps, in one compact design. The con- CAT devices.
nector system is new development and meets the full A specific machine’s design or plant installation is

M More
ANSWERS
A
scope of OCA requirements regarding connected
devices and modules, including drives, sensors and
actuators, electrical cabinets, and entire machine mod-
simplified using PC-based control software tools that
help specify all individual EtherCAT P consumers and
cable lengths to configure the highest performance
KEYWORDS: Power over ules. The benefits of this connector system include: and most cost-effective EtherCAT P network.
Ethernet, EtherCAT,
industrial Ethernet
• Reducing the system to the essentials – name- Connector types: EtherCAT, EtherCAT P
Communications and
power in one-cable design ly the EtherCAT or EtherCAT P communica- If higher power or supplies are required in addition
The various applications tion element and dc or ac power supply lines to the 24 V system and peripheral power supply via
for EtherCAT and power – creates cost-effective connection concepts EtherCAT P, power can be supplied via corresponding
over one cable hybrid cables with the ECP and ENP connector types
Explaining EtherCAT and • The system is easy to use due to the bayonet for this purpose:
EtherCAT P communication connections with mechanical and color coding
with new connector types.
• ECP (EtherCAT P + Power): This connector
CONSIDER THIS: • The power transmission integrated into Ether- series combines a compact, trapezoidal Ether-
How much time or space CAT P can eliminate the four wires normally CAT P element (using the same pin allocation
could an automation design required for 2 x 24 V as the EtherCAT P encoded M8 connector) with
save by using one cable
power and EtherCAT in a
additional power pins. In this way, the 24 V sup-
standard Ethernet cable • Allows the use of thinner, lower-cost cables and, ply integrated into EtherCAT P is complemented
design? alternatively, the supply of other voltages. with an additional power supply line.

• ENP (EtherCAT/Ethernet + Power): These con-

Power over Ethernet (PoE) standards from IEEE nectors combine a trapezoidal, central commu-
Multiple standards in various industries and applications are included in nication element with additional power pins in
Power over Ethernet (PoE). The original PoE task force from The Insti- the same way as ECP. The trapezoidal element
has an inverse design to prevent incorrect con-
tute of Electrical and Electronics Engineers (IEEE) was created in 2000.
nections and provides data transmission via
According to a July 10, 2017, presentation, “Practical PoE Tutorial,” the
EtherCAT, standard Ethernet, or other Ethernet-
standards include: based communication protocols.
Power delivery over BASE-T PHYS (4-pair, 2-pair, 1-pair)
Connector sizes from B12 to B36 are available
• IEEE Std 802.3af-2003 DTE Power via media dependent interface
with a varying number of power pins (two to six
(MDI)
pins) so they can be adapted to the requirements of
• IEEE Std 802.3at-2009 DTE Power Enhancements different network types and the power consumption
for connected consumers. The complete and full-
• IEEE P802.3bt DTE Power via MDI over 4-Pair Task Force
length 360-deg shielding of the central trapezoidal
• 10M/100M/1G/2.5G/5G/10G (4-pair, 2-pair) element continues the typical high-performance of
• IEEE Std 802.3bu-2016 1-Pair Power over Data Lines (PoDL) EtherCAT. (See cable photo on p. 17.)
Expanding the one-cable designs with the grow-
• 10M/100M/1G/10G (2.5G/5G) (1-pair). ing diversity of the EtherCAT P, ECP, and ENP
ISO/IEC standards support PoE, and more are under development. Volt- devices and components also expands the range of
ages and currents were increased from nominal beginnings (14 and 24 V) application options for users. ce
using RJ-45 connectors to larger cables, now up to 50 V (45, 60 W) and
Sree Potluri, I/O application specialist and Andy
52 V (75 and 90 W). See www.ieee802.org for more information.
Garrido, I/O product marketing, Beckhoff Auto-
Mark T. Hoske is content manager, Control Engineering, CFE Media, mation. Edited by Emily Guenther, associate con-
mhoske@cfemedia.com. tent manager, Control Engineering, CFE Media,
eguenther@cfemedia.com.

26 • December 2017 CONTROL ENGINEERING www.controleng.com

ANSWERS
INSIDE MACHINES
Frank Lamb, Automation Consulting LLC
DPM-COUNTERS-TIMERS
UPM-F

Picking the right

discrete sensor for a
machine application
There are many considerations for picking a discrete
BARGRAPHS
sensor for a machine application. These include if the
NTM-M
sensor is being used for position detection or part
detection or if the application is hazardous.

W
hen designing machin- sensors that may have a longer range,
ery, one of the first tasks also should be considered.
for an engineer is to select Visible beam photoelectrics are
discrete sensors for the often easier to align and infrared sen-
application. Generally, discrete sensors can sors also have a longer range. Laser
be divided into two categories: those that sensors, while more expensive, can be
detect the positions of mechanisms and used to detect smaller parts and also
tooling (parts of the machine) and those extend the sensing range.
that detect the parts being processed. The other important consideration
that needs to be made is the voltage
Types of discrete sensors and output type of the sensor. With the COMMON FEATURES
It’s easy for designers to select hall-effect exception of some large conveyor sys- (ALL SERIES)
sensors for pneumatic cylinders since these tems and process control facilities, dis-
often are presented as accessories. Hall- crete sensors are almost always 24 V dc. LOOP/SIGNAL/UNIVERSAL POWER
effect sensors are designed to detect the Positive-negative-positive (PNP) sourc- INPUT SIGNAL FAIL ALARM
magnetic piston inside of a cylinder body ing sensors are used most commonly in
and determine whether it is extended or the U.S., but equipment from other coun- ISOLATED RS485-USB-ETHERNET
retracted. This works fine as long as the tries may use negative-positive-negative
DAS-SCADA-CYBER SECURITY READY
cylinder shaft can’t become unattached (NPN) sensors, or sinking types.
from the tooling; detection of tooling using Sensors with contact closure type out- MIL-NUCLEAR-INDUSTRIAL GRADES
an inductive proximity switch is the only puts such as limit switches also are used AND CUSTOMS
foolproof way to determine that the tool- occasionally, but like ac sensors, they are
ing is in the correct position. becoming less common. Contact closures REMOTE DISPLAY/CONTROLLER
Photoelectric sensors are useful for are best for applications where the sensor ISOLATED 4-20mA/VDC & RELAYS OUT
applications when the tooling is not does not switch often. Physical contacts
made of metal. Photoelectrics and induc- wear and often have a specified lifetime >50 ANALOG INPUT SIGNALS
tive proximity switches often are used for number of operations. 15 DIGITAL INPUT SIGNALS
part detection. Sensor specification depends on a lot
Photoeyes are useful for designers of factors, such as: 1-4 ISOLATED CHANNELS
since they can be located farther from
>40 MODELS!
the target. This opens up several sensing • How much space is available for
possibilities such as through-beam (sepa- mounting LIFETIME WARRANTY/>25 YEAR MTBF
rate emitter and receiver); retroreflective • What type of target is being
SINCE 1974
(using a corner-cube bicycle type reflec- detected
tor or reflective tape); or diffuse (using • With what type of control system it
light reflected off of the target). Form needs to be interfaced
factor, such as fiber optics that can reach
into tight spaces or larger self-contained
• Sensor cost and availability of
replacements.
520-748-7900 MADE IN
THE USA

www.otekcorp.com
www.controleng.com CONTROL ENGINEERING December 2017 • M1
input #7 at www.controleng.com/information
 ANSWERS
Bring Your Machine INSIDE MACHINES

To Life With
Advanced Control ‘ Generally, discrete sensors can be divided
into two categories: those that detect the
Algorithms positions of mechanisms and tooling (parts
Advanced of the machine) and those that detect the
Control

’
parts being processed.
Algorithms

Ethernet
Connectivity

Automation Sensors for harsh conditions

Controller
In some cases, resistance to chemicals and water are also a
Intelligent Drives
consideration. Coolant in metal cutting applications and caus-
Custom Motor
tic washdown liquids in food processing are among substanc-
Design es that may need to be evaluated. This may contribute to the
type of electrical connection the sensor may require; quick dis-
Custom
connect or hard conduit. Automation vendors can help when
Software Vision selecting discrete sensors for a machine application.
Keeping these considerations in mind when making a deci-
sion will make the process much simpler. ce

Frank Lamb, Automation Consulting LLC, is a Control Engineer-

Aerotech can partner with you to design ing Editorial Advisory Board member. Automation Consulting LLC
advanced control algorithms for your is a CFE Media content partner. Edited by Chris Vavra, production
specific application to maximize machine editor, Control Engineering, CFE Media, cvavra@cfemedia.com.
performance.
In our concept machine above, Aerotech’s
standard controller is flexible enough to
control the simple motion of moving the
head to and fro, or the more complicated
M More
ANSWERS
KEYWORD: discrete sensors
coordination of the wings and legs to track Discrete sensors can be divided into two categories: those that
its next meal detected by the vision system. detect the positions of mechanisms and tooling and those that
detect the parts being processed.
Aerotech can accommodate your custom
Photoelectric and hall-effect sensors commonly are used for
automation controller needs by creating discrete applications.
algorithms at the application, motion Depending on the application, resistance to chemicals and water
engine, and/or firmware layer of the also should be considered when picking a discrete sensor
architecture to easily control complicated GO ONLINE
machines. If you have a need for special Read this story online at www.controleng.com for related links.
control algorithms, contact Aerotech today.
CONSIDER THIS
What other considerations should be made when selecting a
discrete sensor?
We customize Aerotech automation for you
• Hardware • Software • HMI • Firmware
• Packaging • I/O • Motors • Electronics
Access the Machine
Global sales, service, and support Vision Digital Report at
The Americas • Europe • Asia-Pacific
www.controleng.com/
Contact our Control Systems Group magazine with the
at 412-967-6839 or
sales@aerotech.com to November 2017 digital
discuss your application today, edition or see all avail-
or see go.aerotech.com/csg101
able Digital reports at
AH0315B-CSG
www.controleng.com/
DigitalReports.
Dedicated to the
Science of Motion
M2 • December 2017 CONTROL ENGINEERING
input #8 at www.controleng.com/information
input #9 at www.controleng.com/information
ANSWERS
II O T FOR OEE
Fritz Cleveland, Banner Engineering

Wireless as a means to
overall equipment efficiency
Accurate machine run-time data helps determine why production
goals aren’t met.

F
ield devices make operations visible
and support data-driven decision mak-
ing. Using technologies associated with
Six ways to lose
the Industrial Internet of Things (IIoT), manufacturing productivity
device-level data is accessible to oper-
ators and plant managers, offering insight into The OEE Foundation identifies 6 “Big
machine performance and process inefficiencies. Losses” to manufacturing productivity:
Real-time remote monitoring of machine status
allows addressing issues as they arise, regardless of 1. Unplanned stops for equipment
whether or not an operator is present. Personnel failure
monitor multiple machines on a factory floor from
a convenient location. Operators resolve small 2. Stops for setup, adjustments, or
issues before they become big problems. changeover
Wireless technology can provide users with
remote-monitoring capabilities on the field- 3. Idling or minor stops (for issues
device level and how this data can be used to help such as a material jam or a blocked
improve overall equipment effectiveness (OEE).
sensor)
Wireless I/O devices are easier 4. Reduced equipment speed
In past, wireless systems were difficult to install
and complicated to maintain. Wireless technolo- 5. Scrapped work
gy has advanced significantly over the years. Today
many remote monitoring solutions offer reliable wire- 6. Rework.
less communication integrated into one, inexpensive
unit. These wireless I/O devices are easy to

M More
ANSWERS
install, and then uninstall and move to a
new location as monitoring requirements
change.
data to another remote serial device. Chaining data
radios expands the network to meet the remote-mon-
itoring needs of many applications.
KEYWORDS:
A wireless I/O device can collect digi-
Overall equipment
effectiveness (OEE), wireless
tal and analog sensor readings and forward An efficiency calculation
Wireless technologies provide
this data to a central collection point for Overall equipment effectiveness (OEE) is a
remote monitoring capabilities. analysis. Several sensors can connect to a calculation of manufacturing process efficiency
OEE components single node, and 47 nodes can exist with- involving three primary factors: availability, per-
Machine health and trends in a single radio network. This means mul- formance, and quality. The availability factor con-
ONLINE EXTRA tiple sensor readings aggregate into one siders events that decrease total runtime, including
See the discrete manufacturing
gateway device before being forwarded to planned stops (such as for product changeover) and
navigation menu at a host-controlled system for analysis. unplanned stops. The performance factor considers
www.controleng.com for related Serial-data radios further extend this anything that decreases the speed of the manufac-
coverage. wireless I/O network. Serial-data radios are turing process while it is running. The quality fac-
CONSIDER THIS back-haul devices that receive serial data tor accounts for parts or products that do not meet
Are your machines making your from another serial-data radio, or a serial quality standards (parts that must be scrapped or
life easier, or more difficult? connection to a gateway, and forward the reworked, resulting in wasted time).

M4 • December 2017 CONTROL ENGINEERING www.controleng.com

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input #10 at www.controleng.com/information

 ANSWERS
II O T FOR OEE

What goes into OEE determine why production goals were not being
An OEE calculation taking these factors met. Operators blamed machine downtime for
into account expresses its result as a percentage the failure and maintenance personnel blamed
value, with 100% meaning only good parts are the operators. Based on the data, facility manag-
made (quality), as quickly as possible (perfor- ers identified what exactly was transpiring.
mance), and without any stops (availability). Cal-
culation results provide actionable insights into A machine’s health
the critical sources of waste in a manufacturing In addition to monitoring machine perfor-
operation. mance metrics, wireless sensor networks also
To reduce OEE losses and minimize their check up on machine health. Machine predictive
impact, visibility into where and when ineffi- maintenance is challenging because minor per-
ciencies occur is essential. This is where access formance changes can be hard to detect without
to data from sensors and indicator lights become the proper tools. Remote condition monitoring
very important. Logged data from sensors and using a wireless system plays a key role in pre-
indicator lights installed on machines can help dictive maintenance and helps prevent costly
calculate OEE and identify steps to improve effi- downtime.
ciency of machines, processes, and people. To take just one brief example, vibration is
a key machine parameter. Machine vibration is
often caused by imbalanced, misaligned, loose, or

‘
worn parts. As vibration increases, so can dam-
By remotely monitoring motors, pumps, age to the machine.
By remotely monitoring motors, pumps,
compressors, fans, blowers, and gearboxes for
compressors, fans, blowers, and gearboxes increases in vibration, problems are detected
before they become severe. A wireless vibration
and temperature sensor serves as a “check engine
for increases in vibration, problems are light” for machines by measuring RMS veloc-
ity, which provides the most uniform measure-
ment of vibration over a wide range of machine

’
detected before they become severe. frequencies.
After mounting the vibration sensor, a user
must collect enough vibration data to estab-
lish a baseline for the machine. Initially set the
Machine runtime trends threshold at 1.5 or 2 times the baseline. When the
Tracking machine and process data trends threshold has been exceeded, the wireless vibra-
helps identify when and where losses are occur- tion and temperature sensor can provide local
ring. However, manually monitoring production indication of the problem, the signal can be sent
machine status is time-consuming. Depending to a wireless tower light on a central location, or
on facility size, manually monitoring machine an email or text alert can be sent. The vibration
status slows down production and requires addi- and temperature data can also be sent to a wire-
tional time more effectively used elsewhere. less logic controller or programmable controller
With a wireless system, on the other hand, for collection and analysis.
using a tower light with a wireless radio base
offers not only local indication of machine sta- Final words on remote monitoring
tus but also remote status of each light module. Remote monitoring capabilities are making it
By logging results from machine-status indica- easier for manufacturers to identify and remedy
tors like tower lights, users can track trends in causes of waste within their facilities. By using
individual machine up-time and cycle counts for wireless technologies, manufacturers can quickly
timely updates. and easily gather data needed for OEE calcula-
Data can be used to identify whether a bot- tions, as well as gain valuable metrics for predic-
tleneck is caused by a machine or personnel tive maintenance to maximize their machine
issue. Capturing machine status helps users performance. ce
identify causes of production loss. This infor-
mation, necessary to identify and drive efficien-
cy improvements, was most likely previously Fritz Cleveland is product manager, wireless prod-
unavailable. ucts, at Banner Engineering; edited by Kevin Parker,
This was the case recently when for one man- senior contributing editor, IIoT for Engineers, CFE
ufacturer accurate machine runtime data helped Media, kparker@cfemedia.com.

M6 • December 2017 CONTROL ENGINEERING www.controleng.com

 INNOVATIONS

®
BACK TO BASICS
Three cybersecurity changes
40 that manufacturers should
M More
INNOVATIONS implement
As connectivity increases, so does the level of
The official ballot is open for voting for Control sophistication in cyber attacks against manufac-
Engineering North American print and digital edition turers and other industries.
subscribers, until Dec. 19. Cast your vote using
CFE Media’s New Products for Engineers platform at
www.controleng.com/NP4E.
Three cybersecurity
recommendations
NEW PRODUCTS 1. Isolate key operations technology
controls from public networks if they
are to be reasonably secure.

2. Governments should encourage

simpler, safer control technology.

3. Market incentives must be realigned

34 for cybersecurity.

34
M More
INNOVATIONS
System Integrator of the Year
www.controleng.com/SIY
GLOBAL SYSTEM INTEGRATOR REPORT
...was mailed with this issue and is available at
www.controleng.com/Magazine under December.
36 Need help on your next project? Find system
integrators by name or various parameters at
www.controleng.com/Global-SI-Database
34 Digital edition includes easy access to supplement
(including this month, Oil & Gas Engineering) and
topical Digital Reports.

36
Looking for new
PE products by category?
Check out the New Products for Engineers Database and
Have a New Product for Engineers to search hundreds of products, with new innovations added
every day.
submit for consideration?
Do so here: www.controleng.com/NP4E Look for this logo on the Control Engineering home page.
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www.controleng.com CONTROL ENGINEERING December 2017 • 33

INNOVATIONS
NEW PRODUCTS FOR ENGINEERS

Apps control functions

of digital pneumatics
Festo Motion Terminal digital piezo pneumatic valves replace more
than 50 components with standard hardware and software apps;
the system saves 70% design time and cuts energy use up to 90%.

F
esto Motion Terminal is said to be the world’s first stan- required. It also can be done directly via the machine’s control
dardized platform that will develop into a “cyber-physi- system. Up to 16 fast analog or digital inputs can be selected for
cal system,” fusing mechanics, electronics, and software. control applications, such as soft stop. System sensors are inte-
The adaptable and flexible system enables design and grated into the actuator, thus facilitating fast control. Energy-
construction of intelligent machines, ensuring Industrie 4.0- efficient basic technologies using piezo valves control the main
ready systems, with use of digital pneumatics. Combining 10 valve stages, allowing for proportional pilot control with mini-
motion apps (40 more are planned) with piezo valve technol- mal energy consumption. Compared to widely used conventional
ogy allows the system to replace more than 50 individual com- solenoid valves, these reduce energy consumption for pilot con-
ponents. These include flow control valves, directional control trol by up to 90%. Among motion apps, Festo developed “ECO
valves, proportional regulators, soft stop components, and drive” or “selectable pressure level” to reduce energy consump-
pneumatic positioning tasks to improve energy efficiency. The tion. It can be supplemented by diagnostic apps to locate leaks.
valve bridge circuit in the valve allows pneumatics to be digi- Design, among the biggest costs in machine and system building,
tized. Ease programming and setup with a CODESYS control- accounts for 25 to 30% of total project cost. Time saved compared
ler with OPC Unified Architecture (UA) expansion capabilities. with designing and parameterizing a modular valve terminal and
With an Ethernet interface and the intuitive web configuration additional individual components is up to 70%. Shipments are
user interface, parameterization of every valve can be done via expected to start in December 2017.
a PC and a web server; no additional configuration software is Festo, www.festo.com/VTEM Input #200 at www.controleng.com/information

Metal-seated ball valves for severe service environments

Conval’s Camseal metal-seated ball valves are designed for severe service environments. The valves are
available in ½- through 4-in. sizes with top entry, socket weld, butt weld, flanged ends and in pressure
classes ranging from ASME 900 through 4500. N and NPT stamped valves are available for nuclear
applications. The Camseal design features zero body, seat, and stem leakage on stand-alone and actu-
ated valves. The ball valves are designed for easy inspection, maintenance, and repair. The cartridge
is removed easily for on-site parts replacement, reassembly, and reinstallation. Other features include
robust stem-ball engagement, bearing support, enhanced chrome carbide coating, and a mounting pad.
Conval, www.conval.com Input #201 at www.controleng.com/information

Surge protective device

Fiber optic microswitch series Phoenix Contact’s Termitrab surge protective
Micronor’s MR386 ZapFREE Microswitch is a fiber optic micro- device (SPD) is designed for measurement and
switch designed to meet the challenging EMC requirements of control applications, and starts from an overall
MRI, medical, and industrial applications. The entirely non- width of 3.5 mm. This means that the protec-
electrical, totally-passive optical sensor provides electromag- tive device can protect up to 572 signals against
netic interference (EMI) and radio frequency interference (RFI) surge voltages on just one meter of DIN rail. The
immunity, isolation from high voltage and lightning, safety in integrated disconnect device is designed to ensure
explosive atmospheres, and can operate interference-free over safe behavior in the event of overload. It signals the
very long distances—up to 4,000 m. Two models—industrial status on each individual protective device mechan-
and MRI safe—are offered. The industrial model targets chal- ically without auxiliary power. Optional remote sig-
lenging environments and features naling modules monitor the status of up to 40 neighboring
an extended temperature range of surge protective devices by means of a photoelectric barrier.
-40 to 80 ºC. Installation is simplified: no additional wiring or program-
Micronor, www.micronor.com ming is required for the protection modules.
Input #202 at www.controleng.com/information Phoenix Contact, www.phoenixcontact.com
Input #203 at www.controleng.com/information

34 • December 2017 CONTROL ENGINEERING www.controleng.com

 See more New Products for Engineers.
www.controleng.com/NP4E PE

Embedded
computer for DAQ applications
Advantech’s MIC-1800 series of data acquisition (DAQ)
embedded computers are a compact platform designed to pro-
vide analog signals and advanced functions such as analog trig-
ger and a waveform generator. The MIC-1800 series feature
multi-function, 16-channel, and 12/16-bit resolution. With up
to a 1MS/s sample rate, users can acquire enough data to dis-
play the measure waveform completely. For analog input, users
can set an analog trigger to start collecting data only when a
certain threshold is crossed, so unnecessary signals can be fil-
Unlock new
tered out. The MIC-1800 series products also have built-in services with your
waveform generators so there is no need to purchase any extra
device. A detachable terminal block that enables direct connec- machines data!
tion with sensor signal lines saves a lot of space and eliminates
some wiring as well. The DIN-rail mounting makes the MIC-
1800 series compatible with distribution boxes and control cab-
inets for many different kinds of machines.
Advantech
www.advantech.com
Input #204 at www.controleng.com/information NEW
Flexy205!
Temperature transmitter IIoT gateway
with intrinsically safe sensor & remote
connections access router
Moore Industries’ THZ3 compact
Dual Input Smart HART Temperature
Transmitter in DIN Rail Mount hous-
ing comes with associated intrinsically ‡ Read & monitor your machine’s
safe (AIS) sensor connections. The AIS data in real-time (alarms, HMIs, etc.)
option allows direct connection of sen-
sors located in hazardous areas since it ‡ Collect data from your PLC and
includes an internal intrinsically-safe push towards value-added services
barrier. The universal mounting bracket (Remote/Cloud)
easily snaps on and off of 35 mm Top Hat DIN-rails and stan-
dard relay tracks. The THZ3-DIN with the AIS option is an ‡ %HQHÀWIURPDZRUOGFODVV
associated apparatus suitable for mounting in non-hazardous
Remote Access solution
or Class I, Division 2/Zone 2 hazardous locations with sensor
input terminals connected to equipment or sensors located
in Class I, II, III, Division 1/Zone 0/1 hazardous locations. ...and much more!
There is no need for the additional cost of an IS barrier, cabi-
net space, high integrity clean ground connection, separate
power supply, or custom vendor backplanes. HZRQEL]ÁH[\
Moore Industries, www.miinet.com
Input #205 at www.controleng.com/information

CONTROL ENGINEERING December 2017 t 35 input #11 at www.controleng.com/information

 INNOVATIONS See more New Products for Engineers.
www.controleng.com/NP4E PE
NEW PRODUCTS FOR ENGINEERS

Pressure transmitter with low-power voltage output

Endress+Hauser added a 1-5 V dc low power output option to the PMP71 pressure
transmitter that draws 17 mW of power at 9 V, making the PMP71 consume less
power. This low-power draw makes the PMP71 ideal for battery- and solar-powered
applications such as remote oil and gas wellheads, offshore platforms, or pumping
stations where low power consumption is critical. The PMP71 measures absolute and
gauge pressure of gas, steam, or liquid and has built-in algorithms to calculate level,
volume, and mass of liquids. Measuring spans are available in ranges from -6 to 6 psi
up to -15 to 10,500 psi. For safe operation at process temperatures up to 752°F, it has a
piezo resistive measuring cell and metallic welded process isolating diaphragm.
Endress+Hauser, www.us.endress.com Input #206 at www.controleng.com/information

Industrial UPS system

Falcon Electric’s SSG industrial uninterruptible power supply (UPS) fam-
ily features a lithium iron phosphate LiFePO4 battery. The online rack-
mount UPS models (1.5 to 6 kVA) provide a longer service life, longer
backup times, lower weight, and higher safety than UPSs with lead-acid
batteries or other LiFePO4 batteries. In addition, the SSG UPS lowers total
cost of ownership (TCO) by reducing costly battery replacements and
downtime. It is designed for continuous use from -20 to 55°C with no performance degradation. It also features no
thermal runaway issues that are inherent in Lithium-ion chemistry with lower lifetime costs.
Falcon Electric Inc., www.falconups.com
Input #207 at www.controleng.com/information

Slim industrial power

supplies 80–480 Watt with
excellent efficiency.

Splicing connectors for

grounding and bonding
The Wago 221 Lever-Nut splicing connec-
tors are UL467-listed for grounding and
bonding applications. Lever-Nuts are built
around Cage Clamp spring connection
technology, which provides well-defined
contact points and high contact force for
TIB series each wire. They are designed to create a
• High power factor by active power correction very low resistance connection, qualify-
• Very high efficiency up to 94.5 % ing them for effective, efficient, and safe
grounding. This additional listing expands
• 150 % peak current for 4 sec the scope of applications for the 221 Series
• Protection against back power, overload and short circuit by providing a tool-less, intuitive, easy-
• Alternative side-mounting for flat panels to-use (and re-use) method for connect-
ing and combining ground wires up to
12 AWG. They can be used in branch cir-
cuit j-boxes in commercial and residential
construction as well as in industrial con-
trol cabinets.
Wago Corp., www.wago.com
Reliable. Available. Now. www.tracopower.com Input #208 at www.controleng.com/information

input #12 at www.controleng.com/information 36 • December 2017

UK_en_TIB_CE_Third_4.5x4.625inch.indd 1 20.11.17 10:10

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www.controleng.com CONTROL ENGINEERING December 2017 • 37
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38 • December 2017 CONTROL ENGINEERING www.controleng.com

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www.controleng.com CONTROL ENGINEERING December 2017 • 39

 INNOVATIONS
BACK TO BASICS
Gregory Hale, ISSSource

Three cybersecurity changes that

manufacturers should implement
As connectivity increases, so does the level of sophistication in cyber attacks against manufacturers
and other industries. Three security recommendations for manufacturers are highlighted.

I
t is difficult to paint a rosy picture of security 2. Governments should support a
today. Attacks are more sophisticated and the market for simpler, safer control
attack surface has broadened. There aren’t any technology.
easy answers, but the reality is there are solu- In this world, complexity is the enemy and mal-
tions and manufacturers can win in the end. ware is easy to insert into the millions of lines of
“The systems you are in charge of are under code. In addition, he said, general-purpose micro-
attack,” said Dr. Joel Brenner, MIT/Internet Pol- chips and general purpose controls are unsuitable for
icy Research Initiative (IPRI)-CIS during his key- controlling sensitive OT.
note address at the Industrial Controls System Joint “If we are going to have simpler controls, there
Working Group 2017 Fall Meeting in Pittsburgh, has to be a market for them—and it needs support
in September. “The ability to carry out the attack from governments across the world,” he said.
are not only with nation states, but by well-fund-
ed attack groups.” That means critical sectors need 3. Market incentives must be realigned
protection, but keeping all the critical areas secure for cybersecurity.
would not be possible. Retirement of legacy systems should be a priority.
“There are critical sectors and then there are really Brenner said governments should create tax incen-
critical sectors,” Brenner said, breaking the critical areas tives to accelerate the retirement of legacy systems.

M More
INNOVATIONS
into four key sectors. “The four sectors are oil and gas,
financial, electricity, and communications.”
Recent attacks on the British national health-
When it all comes down to it, he said, “The most
difficult cybersecurity challenges are economic and
political—not technological.”
KEYWORDS:
cybersecurity, IIoT care services, Ukrainian power suppliers, Saudi oil He believes the main challenge in doing security
Cybersecurity attacks company Aramco, and Qatari gas enterprise Ras research is to quantify network risk.
against manufacturers are Gas demonstrate that there have been an increas- There needs to be more facts and figures; the
more sophisticated and ing amount of assaults against critical infrastructure inability to quantify risk impedes security.
are targeting more areas organizations. While there are advantages to a more “The biggest issue of risk is not the silicon-based
than ever before.
digital manufacturing enterprise, there are dangers. element in the computers, it is the carbon-based unit
Companies need
to isolate operations
Increased connectivity, digitization, and applica- in the chair,” Brenner said.
technology (OT) from the tion of the Industrial Internet of Things (IIoT) can The industry has been working on security issues
network and governments make companies more vulnerable to new types of for 20 years and Brenner doesn’t feel there has been
should support simpler attacks. any real difference in risk.
and safer control Brenner offered three security recommendations “We have been facing the consequences of 20
technology.
for manufacturers: years of wishful thinking,” he said.
Cybersecurity may have
improved, but companies “Cybersecurity is not getting any better. We
are not more secure. 1. Key operations technology (OT) have been walking backward on cybersecurity for
controls must be isolated from public 20 years. Your security may be better, but we are
GO ONLINE networks if they are to be reasonably not more secure. We have got to understand the
Read this story online secure. fundamental problems are political and connected
at www.controleng.com
for additional stories Not all networks need to be segregated, only key to national will. Now is the time to be clear head-
from Gregory Hale about aspects of OT controls, he said. He admitted there ed and honest with ourselves on the depth of the
cybersecurity. are differences of opinion about appropriate degrees problem.” ce
of separation. “Taking control off the internet does
CONSIDER THIS
not mean taking it away from digital,” he said. “Not Gregory Hale is the editor and founder of Industrial
What else can
companies do to protect all functions need to be facing the public internet. Safety and Security Source (ISSSource.com), a CFE
themselves from potential Some functions need to be locked up. There are lots Media content partner. Edited by Chris Vavra, pro-
cybersecurity attacks? of ways to figure out how to isolate.” duction editor, CFE Media, cvavra@cfemedia.com.

40 • December 2017 CONTROL ENGINEERING www.controleng.com

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input #13 at www.controleng.com/information

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